Maskless Solid Freeform Fabrication of Dense Metal Micro- and Meso-scale Structures

本研究的目的是创建一种软件可重构的固体自由形状制造工具，能够制造尺寸小于100微米的致密金属结构。该方法是开发和优化一种工具，该工具由高分辨率，多阳极，电沉积打印头组成，可以微定位在阴极衬底之上。电沉积打印头的每个阳极都具有一个直径小于100微米的互补电解质注入器，允许金属电沉积高度定位。在衬底上方光栅化头部，同时控制沉积电流和电解质流动，允许三维多材料结构的逐层生长。对磁头耐久性、阴极基板上的流动和电流的相互作用以及已建结构的释放进行基础研究，将指导工具的设计和优化。如果成功，这项研究的好处包括开发一种新的、灵活的制造金属微结构的方法。该工具的逐层构建过程是严格的添加剂，并且涉及具有广泛功能特性的材料，允许大量的设计灵活性。这项工作的成功将影响许多行业，包括航空航天、通信、医疗保健、信息技术、安全和国防部门。毕业后，这两名从事这项研究项目的高级学位学生可能会为美国的制造业竞争力做出贡献。

The objective of this research is to create a software reconfigurable solid freeform fabrication tool capable of manufacturing dense metal structures with dimensions below 100 micrometers. The approach is to develop and optimize a tool comprised of a high resolution, multiple anode, electro-deposition print head that can be micro-positioned above a cathode substrate. Each anode in the electro-deposition print head possesses a complementary electrolyte injector with a diameter below 100 micrometers, allowing metal electro-deposition to be highly localized. Rastering the head above the substrate, while simultaneously controlling the deposition current and electrolyte flow, permits the layer-by-layer growth of three-dimensional multi-material structures. Fundamental studies of the head durability, interaction of the flow and current at the cathode substrate, as well as the release of built structures, will guide the tool design and optimization.If successful, the benefits of this research include the development of a new, flexible, approach for manufacturing metal microstructures. The layer-by-layer build process of this tool is strictly additive, and involves materials with a wide range of functional properties, allowing substantial design flexibility. The success of this work will impact numerous industries, including aerospace, communications, health care, information technology, security, and defense sectors. Upon graduation, the two advanced degree students working on this research project will likely contribute to the manufacturing competitiveness of the United States.