Hybridizing 3D printing and electroplating for the controlled forming of metal structures within fused deposition modelled contours

Abstract An innovative approach for metal electroforming is presented, exemplified with proof-of-concept geometries and illustrated with an industrial application. The proposed production chain hybridizes 3D polymer printing and nickel electroplating for the design-controlled forming of metals within fused deposition modelled contours or patterns, which provide a selective functionalization of the substrate for metal deposition on demand. Applying the developed process, Ni electrodes for streamer discharge plasma generators are structured. These components stand out for their needle-like details, required for promoting streamer discharge phenomena, which would be challenging to obtain employing traditional milling processes. Current capabilities, main challenges and foreseen research directions, for this novel hybrid 3D printing and electroplating process and for its industrial applications, are discussed. Overall, the described process contributes to the already fruitful connections among additive manufacturing technologies and metal electrodeposition procedures, providing an interesting route towards accessible and straightforward electroforming of large components and structures.