A Low-Cost Electrochemical Metal 3D Printer Based on a Microfluidic System for Printing Mesoscale Objects

Abstract

For the additive manufacturing (AM) of metal objects, the powder-based fusion (PBF) method is routinely utilized to fabricate macroscale parts. On the other hand, electrochemical additive manufacturing (ECAM), in which metallic structures are deposited through the electrochemical reduction of metal ions, is a promising technique for producing micro- and nanoscale objects. However, a gap exists in terms of fabricating mesoscale objects within the current AM techniques. The PBF method is limited by fabrication precision due to pronounced residual stresses, and most current ECAM systems are difficult to scale up to print mesoscale objects. In the present paper, the novel design of a low-cost ECAM 3D printer based on a microfluidic system is proposed for fabricating mesoscale metal parts. The meniscus-guided electrodeposition approach is utilized, in which a meniscus is formed between the print head and substrate, and electrodeposition is confined within the meniscus. A 3D object is fabricated by the meniscus moving with the print head according to the programmed pattern and the material subsequently being deposited at the designated locations. The key to the proposed design is to maintain a mesoscale meniscus, which normally cannot be sustained by the electrolyte surface tension with a print nozzle having a mesoscale diameter. Therefore, a microfluidic system, called the fountain pen feed system, constituting a semi-open main channel and comb structure, was designed to maintain a mesoscale meniscus throughout the printing process. Two materials, copper and nickel, with various geometric shapes were attempted to print by the proposed ECAM system, and, during the printing process, both fluid leaking and meniscus breaking were completely prevented. Free standing tilted copper pillars with controlled angles were printed to show the ability of the proposed design in fabricating 3D structures. A copper circuit was also printed on a non-conductive substrate to demonstrate a possible application of the proposed ECAM system in the fabrication of functional electronics.

The rise of continuous flow biocatalysis – fundamentals, very recent developments and future perspectives

“…However, the most suitable technology for meso-scale reactors with 3D printing is electrochemical additive manufacturing (ECAM), in which metal ions are deposited as metal atoms by electrochemical processes. 202 Many steps have already been taken with regard to 3D printing, but some have yet to be taken, such as the chemical refinement of printed devices, which has received much less attention. Various research groups are now focusing to fill this gap by developing initial proof-of-concept studies for modifying and functionalizing 3D printing surfaces and devices, paving the way for a new strategy that combines enzyme immobilization, its recyclability and continuous flow processes.…”

Modelling Approach in the Development of Electrochemical 3d-Printing Systems

“…Останнім часом з'являється все більше робіт, присвячених дослідженням 3D-друку металевих об'єктів із використанням електрохімічного осадження металів [4,[6][7][8][9][10][11][12][13][14][15]. Цей спосіб 3D-друку потенційно є найбільш енергоефективним і найменш матеріаловитратним, а також простим у реалізації.…”

“…Другий спосіб [4,[12][13][14][15] полягає в тому, що між робочою поверхнею катода та кінцем капіляра, завдяки регулюванню тиску електроліту в капілярі, реалізовано стійкий контрольований "меніскний" стовп рідини, під яким на поверхні катода відбувається електроосадження металу.…”

Experimental Analysis of Wax Micro-Droplet 3D Printing Based on a High-Voltage Electric Field-Driven Jet Deposition Technology

“…Micro/nano 3D printing technology is a new micro/nano manufacturing method based on the principle of additive manufacturing. It can directly print and form functional products with a micro/nano characteristic structure [1]. Compared with traditional LIGA (Lithographie, Galvanoformung and Abformung) technology [2], nano-lithography [3], micro/nano embossing [4], high-speed micro-milling, micro-electrical discharge machining (EDM) [5], and other micro/nano manufacturing technologies, micro/nano 3D printing technology has the advantages of being a simple manufacturing process, being low in cost, and of allowing for high utilization of materials, wide material application, and direct formation.…”