Electroforming in the Industry 4.0 Era

Roy, Sudipta; Andreou, Eleni

doi:10.1016/j.coelec.2020.02.025

Cited by 13 publications

(10 citation statements)

References 44 publications

(67 reference statements)

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“…Since very low stress is required for aerospace applications, additives are not used, and these inherent characteristics of nickel sulphamate electrolytes are an advantage. The anode area was twice as that of the cathode to avoid anode passivation (Roy and Andreou, 2020). The disk electrode was rotating at 1,500 rpm.…”

Section: Materials and Methodologymentioning

confidence: 99%

“…Even though nickel electroforms present exceptional mechanical properties and low to zero internal stresses (Committee B-8 Staff, 1962;Popereka, 1970;Uriondo et al, 2015;Davies and Jenkins, 2014;Jianhua et al, 2016;Zhu et al, 2006;Zhu et al, 2008;Li et al, 2019;Khazi and Mescheder, 2019) rendering electroforming a promising manufacturing process for "heavy" industries, our current knowledge base is derived predominantly from empirical data since scientific research has been limited. As it has been reported already (Roy and Andreou, 2020), although there is a huge volume of empirical data, more in-depth scientific analysis, amenable to predictive modelling, is needed. Most importantly, for volume manufacturing, systematic experimental and modelling investigations in the laboratory, and thereafter scaling-up to industrial conditions, are required.…”

Section: Introductionmentioning

confidence: 99%

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Modelling the Scaling-Up of the Nickel Electroforming Process

Andreou

Roy

2022

Front. Chem. Eng.

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Electroforming is increasingly gaining recognition as a promising and sustainable additive manufacturing process of the “Industry 4.0” era. Numerous important laboratory-scale studies try to shed light onto the pressing question as to which are the best industry approaches to be followed towards the process’s optimisation. One of the most common laboratory-scale apparatus to gather electrochemical data is the rotating disk electrode (RDE). However, for electroforming to be successfully optimised and efficiently applied in industry, systematic scale up studies need to be conducted. Nowadays, well-informed simulations can provide a much-desired insight into the novelties and limits of the process, and therefore, scaling up modelling studies are of essence. Targeted investigations on how the size and geometry of an electroforming reactor can affect the final product could lead to process optimisation through simple modifications of the setup itself, allowing immediate time- and cost-effective adjustments within existing production lines. This means that the accuracy of results that any scaled up model provides, if compared to a successful, smaller scale version of itself, needs to be investigated. In this work a 3-D electrodeposition model of an RDE was used to conduct geometry and model sensitivity studies using a commercial software as is often done in industry. As a next step, a 3-D model of an industrial-scale electroforming reactor, which was 90 times larger in electrolyte volume compared to the RDE, was developed to compare, and identify the key model parameters during scale up. The model results were validated against experimental data collected in the laboratory for both cases to assess model validity.

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Section: Materials and Methodologymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Modelling the Scaling-Up of the Nickel Electroforming Process

Andreou

Roy

2022

Front. Chem. Eng.

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“…137,138 Industry 4.0 implementation in electroforming can result in increased productivity through the optimization and automation of the process, improved quality through real-time quality control and predictive maintenance, reduced costs through predictive maintenance and big data analytics, flexibility in producing high precision components for a variety of industries, and sustainability due to its environmentally friendly process that uses less material and energy than traditional methods. 24…”

Section: Advance Digitization and Automation In Electroformingmentioning

confidence: 99%

Review—Electroforming Process for Microsystems Fabrication

Rai,

Gupta

2023

J. Electrochem. Soc.

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Being an unconventional technique of additive micro-manufacturing, electroforming has garnered significant interest by various industrial sectors because of its capability to offer advanced micro-manufacturing competences with high precision in achieving dimensional uniformity and replication accuracy at small scale. This paper reports a comprehensive review of the electroforming process as a microsystem fabrication technique. This process is superior compared to 3D printing, stereolithography, selective laser sintering, and fused deposition modeling etc., in many aspects due to its unique properties. It can deposit a wide variety of metals and alloys, including precious metals, making it appropriate for variegated applications in microfabrication domain. We cover the fundamental aspects of electroforming and its history followed by the current state of the art advancement, modelling associated with it, and its importance from industrial context. Additionally, we discuss the advantages and limitations of this technique and their respective microsystems applications. Finally, we conclude with a discussion on the future prospects and potential advancements in the field of electroforming contributing to micro-systems development.

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“…In 1978, Bergh and Alkire [8] applied FEM to study shape evolution during electrodeposition, concluding that the application of the method should be pursued further to allow modelling of complex electrochemical systems. Later on, Deconinck et al [9] [10] introduced the boundary element method (BEM) to model evolving electrode profiles when non-linear boundary conditions are in place. Among their findings, a relation between electrode shape changes and reactor dimension for different angles between the electrode and an adjacent insulator was established.…”

Section: Key Modelling Studies Of Electroformingmentioning

confidence: 99%

Modelling the electroforming process: significance and challenges

Andreou

Roy

2021

Transactions of the IMF

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Electrochemical forming (or electroforming), is gaining recognition as an additive and sustainable manufacturing process. Electroforming could shape part of the fourth industrial revolution through thoughtful and systematic modelling. For this to be useful, efficient simulation of the electroforming process in 4.0 era should be used as a tool to design, test and propose optimised processes. Emphasis should be put on building models that provide new information about the electrochemical systems under investigation or lay the groundwork for innovative applications and provide the industry with options to update obsolete process models currently in use. This will lead to a decrease in process waste, lower inventory needs, perhaps meet environmental regulations and optimise supply chains. In this review article, key studies on modelling electroforming processes are critically reviewed against this framework. The authors suggest some useful modelling approaches using commercial software.

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Electroforming in the Industry 4.0 Era

Cited by 13 publications

References 44 publications

Modelling the Scaling-Up of the Nickel Electroforming Process

Modelling the Scaling-Up of the Nickel Electroforming Process

Review—Electroforming Process for Microsystems Fabrication

Modelling the electroforming process: significance and challenges

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