Engineering Design Conference

This project combines electrochemical additive manufacturing (ECAM) and electrochemical machining (ECM) into a single machine. ECAM is a form of additive manufacturing that utilizes a chemical reaction between the tool (anode) and the build plate (cathode) to create localized material depositions. This can be used to effectively 3D-print microscopic metal parts. Conversely, ECM is a subtractive process. By reversing the polarity of the hybrid system, material can be removed rather than deposited. While these processes have achieved success individually, this project is the first to incorporate both functions into a single machine. The process is completely non-contact and creates no tool wear. This process allows for high-precision machining on the micrometer scale. A three-axis movement system was used with gearing to provide precise movement. The motion information is programmed from G-code, which is hosted on a Raspberry Pi and interacts with a smart motor-driver board. To control the material deposition, a PWM driver and amplifier stage are used to create an adjustable pulse signal which facilitates the deposition or removal of material.

At Grand Valley State University, we empower learners in their pursuits, professions, and purpose. The University enriches society through excellent teaching, active scholarship, advancement of equity, and public service.