Recently, a research team at Imperial College London in the UK has developed a new low-cost metal 3D printing process called Electrochemical Additive Manufacturing (ECAM). It is reported that this innovative technology uses electroplating technology to create metal objects in a low cost manner.
This novel process was recently published in the journal Advanced Materials Technologies under the title "Low-cost benchtop electrochemical metal 3D printer." The AM system was developed by engineers Billy Wu, Xia Xiaolong Chen, Xinhua Liu, Peter Childs and Nigel Brandon.
Researchers say that because of the high cost of metal 3D printing, they are mainly used to develop metal 3D printers. While FDM and most polymer-based 3D printing technologies have a range of affordable systems, metallic 3D printing remains an expensive technology.
The high price dictated by material costs, expensive laser systems, and the demand for gases such as argon means metal 3D printing is limited to high-end industrial applications in the medical, aerospace and automotive industries.
ECAM is a new technology developed by Imperial College London that provides a metal 3D printing platform that is easier to access than existing systems.
Instead of using a laser to melt and sinter metal powder, ECAM uses an electroplating system, a process traditionally used for gold jewelry plating, to build metal parts layer by layer.
Dr. Billy Wu further explained the process: "Here, metal ions in solution, such as Cu2+ ions in copper sulfate, are reduced to their elemental composition by applying an external potential."
“In our electrochemical 3D printer, the ionic solution is loaded into the syringe and a meniscus is formed between the nozzle and the conductive plate. The potential is then applied to deposit the metal and cause the printhead to move. This process continues until the 3D object is created. ," he continued.
In other words, the ECAM3D printer uses a metal ion solution as a material and as a conductive substrate for the build surface to make metal parts. The nozzle deposits a metal ion solution onto the conductive substrate in tiny droplets, resulting in electrochemical reduction of the metal ions.
According to the research team, this new approach has many benefits. First, it is less expensive than laser and gas based AM systems. Second, the technology can be used for 3D printed structures of a variety of different materials and alloys, and "without thermal damage under ambient conditions."
Third, the ECAM method can also be used as a material reduction manufacturing method by "reversing potential". This means that the process can convert the printed metal into a solution by electrochemical dissolution, which allows the metal material to be recycled.
Fourth, the researchers say that the ECAM 3D printing process can be adapted to incorporate multiple printheads, which enables multi-material metal 3D printing. However, one current drawback of this technology is that the printing speed is quite slow.
Billy Wu said: "Whether metal 3D printing technology is likely to open up new design possibilities and become a future distribution manufacturing method, but it is not clear when the technology will be commercialized."
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