Hybrid Additive Manufacturing Method for Selective Plating of Freeform Circuitry on 3D Printed Plastic Structure

Abstract

This work proposes a hybrid additive manufacturing method coupling the advantages of dual‐material fused deposition modeling (FDM) 3D printing and selective electroless plating. The method relies on the selective sensitization/activation and metallization of dual‐material FDM 3D printed structure. High‐conductive nickel alloy can only be deposited on the platable plastic surface leaving the nonplatable plastic bare. The study reveals that a combination of acrylonitrile‐butadiene‐styrene and polyethylene terephthalate glycol‐modified materials provides the best metallization selectivity and film adhesion strength. The effects of electroless plating parameters such as temperature, pH value, and duration on the electrical conductivity of metallic film are systematically investigated. Through four‐point probe measurement, energy‐dispersive X‐ray spectroscopy inspection, and scanning electron microscopy cross‐section analysis, it is found that the metal deposition rate majorly depends on the plating temperature, while the composition of plated film is mainly determined by the pH value. Thus, the conductivity of metallic film can be customized according to the detailed requirements of practical applications. A minimal resistivity of 6.7 × 10−5 Ω cm is obtained when electrolessly plated at 50 °C and pH 9. A light‐emitting diode (LED) blinking circuitry is fabricated in both 2D and 3D manners as demonstrators to prove the feasibility and potential of this technology in industry applications.

Investigation on the mechanical properties of additively manufactured PETG composites reinforced with OMMT nanoclay and carbon fibers

“…[31] 3D printing and selective electroless plating of PETG and ABS based was useful in fabricating customized electronic systems for aviation, aerospace, automotive, and medical instruments. [32,33] PETG and other polymers like Polyetheretherketone (PEEK), polymethyl methacrylate (PMMA), and polyvinylidene fluoride (PVDF) are favorable for medical load-bearing applications like orthotics and other applications like sutures or mesh. [34] Carbon fiber reinforced PETG composites were 3D printed to cater to customized ankle-foot orthotic requirements for medical applications.…”

Modifying Metastable Sr1–xBO3−δ (B = Nb, Ta, and Mo) Perovskites for Electrode Materials

“…The electrical resistivities (ρ), plotted from −5.0 to 5.0 V, were calculated by applying Ohm’s and Pouillet’s laws. 59 The current value for as-synthesized SBO NPs was beyond the detection resolution of the instrument due to their intensely insulating nature, but demonstrated a systematic decrease in resistivity (1.1 × 10 3 Ω cm for 6 h) with treatment time ( Figure 5 a). Although a similar quantitative ρ reduction was observed for SMO (from 2.6 × 10 –4 Ω cm for 4 h to 1.7 × 10 –4 Ω cm for 6 h; Figures 5 b and S10 ), a nonohmic response was observed for the STaO after 6 h ( Figure 5 c).…”

Multiscale Evaluation of The Elastic Behavior for The Metal-Coated Lattice Structures

“…Metallic coating treatment for 3D printed resin lattice structure is studied by a research team from Southeast University [31], [32]. Metallic coating is deposited on the surface of test sample via electroless plating process which includes four major steps [31]: (1) etching, (2) sensitization/activation, (3) acceleration, and (4) plating. Test samples are first ultrasonically cleaned in isopropanol (C3H8O), and then immersed in strong KMnO4 etchant for roughening the sample surface.…”