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Nickel vapour deposition is a two stage chemical process in which bulk nickel powder is converted into solid nickel shells. In the vapourization stage, nickel powder is combined with carbon monoxide to form carbonyl gas. In the deposition stage, the carbonyl gas is broken down into pure nickel and carbon monoxide when it encounters the heated surface of a substrate mandrel. Solid nickel is deposited on to the heated mandrel surface and carbon monoxide is collected to be re-used in the vapourization stage.

The deposition of nickel occurs atom by atom, producing an exact replica of the mandrel surface. The resulting shell is 99.98% pure nickel with no residual stresses. Tools made using NVD nickel shells offer many flexible design options and critical advantages not available with any other tool-making technology.

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