A new manufacturing process combining 3D printing and electroplating has been developed to create complex metal structures with fine details. The hybrid method uses fused filament fabrication (FFF) 3D printing to create polymer masks that guide the electrochemical deposition of metals, allowing for precise control over the final metal components’ shape and features.
The research team utilized a Prusa i3 Mk3S printer equipped with a 0.25mm nozzle to achieve higher resolution printing of the polymer masks. These masks were printed onto 4-inch silicon wafers coated with a titanium/titanium oxide layer, which serves as the conductive substrate for the subsequent electroplating process.
Testing revealed that acrylonitrile styrene acrylate (ASA) proved to be one of the most suitable materials for the process, demonstrating strong adhesion strength of 4.3 MPa and easy dissolution in common solvents after electroplating. The team successfully created nickel structures ranging from 500 micrometers to 2 millimeters in height using a nickel sulfamate electrolyte bath maintained at 52°C.
To demonstrate practical applications, the researchers produced specialized L-shaped electrodes with varying tip designs for use in streamer discharge plasma generators. The electrodes underwent systematic testing using voltages between 0 and 6 kV to evaluate their performance in plasma generation applications.
The new manufacturing approach offers advantages over traditional metal fabrication methods, particularly for creating complex shapes that would be challenging to achieve through conventional machining. While the process shows promise for industrial applications, the researchers note that uneven metal distribution during electroplating remains a limitation that requires careful control of process parameters.
Source: link.springer.com