A Novel Electrochemical Micro Additive Manufacturing Method of Overhanging Metal Parts without Reliance on Support Structures

Abstract

A simple case study of support structure-less, voxel-by-voxel electrochemical deposition of a 3D part at the micro scale is introduced. This method allows for the creation of overhanging parts without reliance on support structures, which are difficult if not impossible to remove at the micro/nano scale. Standard values and procedures are established in order to create design rules for the electrochemical deposition process. The voxel size, tool clearance values, raster path generation, approach and retract paths, and part segmentation rules are established. The algorithm was then executed on a sample part and successful performance was verified. This lays the foundation for future experimental verification and commercial adoption of the proposed method.