Miniaturization of industrial equipment and products focuses on reducing dimension, volume, and weight while enhancing production speed. Metallic micro and meso-components are increasingly utilized across various critical industries, including automotive, electronics, robotics, biomedical engineering, and aerospace. This study examines the impact of electric current density on the hardness and microstructure of meso-components fabricated using a rapid tooling and electroforming process, which is both cost-effective and relatively fast. A series of polymeric moulds were created through VAT polymerization, followed by electroforming to produce metallic meso-components replicating these moulds. The metallic components, made from copper, were studied over a current density range of 1–9 A/dm2.The study investigates the effect of current density on the microstructure and hardness of electroformed copper specimens. At an optimal current density of 5 A/dm2, a significant reduction in average grain size was observed, decreasing from 6.6 to 1.2 µm, accompanied by an increase in hardness from 79.4 to 117.8 HV. However, at 9 A/dm2, the microstructure transitioned from a spherical to a needle-shaped structure, and the formation of microcracks was observed, leading to a reduction in structural integrity and a decrease in hardness in the regions with cracks. This study highlights the crucial role of optimized current density in determining the hardness, quality, and manufacturing time of meso-components produced via electroforming. The findings of this study can be applied to further investigations of electroforming performance, aiming to minimize defects and identify the optimal current density for meso-component fabrication.