Electroforming 3D Metal Parts from Printed Conductors

This award supports research to investigate electroforming of 3D metal parts from conductors printed using polymer-based 3D printers that are more widely available and cheaper than current metal 3D printers. Metal 3D printing has been revolutionary for creating complex metal parts but remains expensive, low resolution and limited in material selection. Electroforming, on the other hand, is used for low-cost metal parts from automotive components to compact disk masters but lacks the versatility to create complex geometries provided by 3D printing. This research project will develop an approach for creating complex metal parts at reduced cost as well as improved understanding of electroforming into complicated 3D geometries that will more broadly impact an important US industry. The outcomes of this work are expected to advance US prosperity through an advanced manufacturing process to improve access to metal 3D printing at reduced cost. The project also includes efforts to strengthen the STEM workforce for printable electronics and 3D printing through educational activities. In this research program, a framework will be developed for understanding the relationship between printed 3D structured dielectrics and conductors on the electroforming process, improving understanding of the effects of printed dielectric shielding and other supporting structures such as secondary cathodes on electroforming within complex 3D geometries traditionally difficult to electroform. The research will generate a fundamental mechanistic understanding of electroforming in 3D topographies (e.g., dielectric shielding, secondary cathodes, and controlled electrode bridging) and provide a systematic design framework that could make metal part fabrication more accessible than conventional metal additive manufacturing. The resulting manufacturing process will be a major advance in reducing the cost and increasing the availability of complex metal 3D parts. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria. NSF Award ID: 2609494 | Program: 01002627DB NSF RESEARCH & RELATED ACTIVIT | Principal Investigator: Nathan Lazarus | Institution: University of Delaware, NEWARK, DE | Award Amount: $250,166 View on NSF Award Search: https://www.nsf.gov/awardsearch/show-award/?AWD_ID=2609494 View on Research.gov: https://www.research.gov/awardapi-service/v1/awards/2609494.html