In the ever-evolving landscape of manufacturing, a groundbreaking study from the Leibniz Institute of Polymer Research Dresden e.V. is set to revolutionize the way we think about additive manufacturing and metal plating. Led by Philipp Zimmermann, the research, published in ‘Macromolecular Materials and Engineering’ (Macromolecular Materials and Engineering is translated to English as Macromolecular Engineering), introduces a novel process that could significantly impact the energy sector and beyond.
At the heart of this innovation is acrylonitrile butadiene styrene (ABS), a polymer widely used in both the galvanic industry and Fused Filament Fabrication (FFF), a type of 3D printing. Traditionally, ABS surfaces are etched in chromosulfuric acid to facilitate metal deposition. However, the use of chromium (VI) compounds has been restricted in the European Union since 2017, prompting the need for alternative methods.
Zimmermann and his team have developed a new plating process that bypasses the need for etching. Instead, they convert double bonds on the ABS surface to epoxides, followed by grafting a polyethylenimine (PEI) to the surface. This modified plastic serves as an ideal substrate for metal plating, opening up new possibilities for industrial applications.
One of the key challenges in additive manufacturing is the formation of voids between strands and layers, which can hinder subsequent wet processing. The new plating process demands high water tightness, a requirement that the proposed printing procedure meets with remarkable success. “We’ve reduced the degree of water penetration from 50% to less than 0.1% at 2 bar water pressure,” Zimmermann explains. This level of water tightness is crucial for the deposition of industrial-relevant nickel (Ni) layers, a process that has shown high adhesion to ABS in cross-hatch and peel tests.
The implications of this research are far-reaching, particularly for the energy sector. The ability to produce watertight, metal-plated ABS parts could lead to the development of more durable and efficient components for renewable energy systems, such as wind turbines and solar panels. Moreover, the elimination of chromium (VI) compounds aligns with the EU’s environmental regulations, paving the way for more sustainable manufacturing practices.
As we look to the future, this research could shape the development of new materials and processes in additive manufacturing. The combination of the new printing procedure and the innovative plating process sets a new standard for quality and sustainability. “This is just the beginning,” Zimmermann notes. “We’re excited to see how this technology will evolve and impact various industries.”
The study, published in Macromolecular Engineering, marks a significant step forward in the field of additive manufacturing and metal plating. As the energy sector continues to grow and evolve, innovations like these will be crucial in meeting the demands of a sustainable future. The research from the Leibniz Institute of Polymer Research Dresden e.V. is a testament to the power of innovation and its potential to transform industries.