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<p>Electroforming is a promising manufacturing process for producing precise and customized metal components, making it suitable for personalized and small-batch production. Combining electroforming with fused deposition modeling (FDM)-produced molds offers a cost-effective and adaptable method for fabricating complex metal parts. Recent studies have demonstrated its ability to create intricate multi-level and free-form geometries with significant thicknesses. This study focuses on examining how electrode placement influences copper deposition during electroforming in FDM molds. A simulation model is developed and utilized as a tool to visualize copper growth and evaluate the impact of various electrode configurations on deposition uniformity and accuracy. Experimental validation supports the simulation findings, leading to the development of practical design guidelines for optimal mold design and electrode placement. This research contributes to advancing electroforming in 3D-printed molds as an efficient and scalable solution for producing high-quality, customized metal components.</p>

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Simulation of electroforming in additive molds to devise part manufacturing

  • 期刊论文

  • 发表日期：

    2025年2月8日

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  • Hazem Hamed,
  • Rolf Wüthrich,
  • Jana D. Abou Ziki

摘要

Electroforming is a promising manufacturing process for producing precise and customized metal components, making it suitable for personalized and small-batch production. Combining electroforming with fused deposition modeling (FDM)-produced molds offers a cost-effective and adaptable method for fabricating complex metal parts. Recent studies have demonstrated its ability to create intricate multi-level and free-form geometries with significant thicknesses. This study focuses on examining how electrode placement influences copper deposition during electroforming in FDM molds. A simulation model is developed and utilized as a tool to visualize copper growth and evaluate the impact of various electrode configurations on deposition uniformity and accuracy. Experimental validation supports the simulation findings, leading to the development of practical design guidelines for optimal mold design and electrode placement. This research contributes to advancing electroforming in 3D-printed molds as an efficient and scalable solution for producing high-quality, customized metal components.