A method for producing a 3D structure, according g to which a composite conductive substrate (CCS) with a conductive layer and a non-conductive layer is provided and a conductive pattern is determined for each layer of the 3D structure. A first layer of non-conductive matter on the CCS is printed, such that the conductive pattern of the first layer left empty from the non-conductive matter. The empty conductive pattern is filled with conductive matter by electroplating and for each following layer, in turn, printing, on the previous layer, a layer of non-conductive matter, the conductive pattern of the present layer left empty from the non-conductive matter; plating non-conductive areas of the previous layer that are left uncoated with conductive matter; and filling the empty conductive pattern of the present layer with conductive matter by electroplating.

The invention provides a device and a method for manufacturing 3D metal structures by a sequence of electroplating steps, each step adding a cross-section layer of the 3D structure via anodes, selected from a planar 2D anode grid array and forming a pattern template, creating a deposition image on a cathode plate.

Process for manufacturing a printhead for a 3D manufacturing system that uses metal electrodeposition to construct parts. The printhead may be constructed by depositing layers on top of a backplane that contains control and power circuits. Deposited layers may include insulating layers and an anode layer that contain deposition anodes that are in contact with the electrolyte to drive electrodeposition. Insulating layers may for example be constructed of silicon nitride or silicon dioxide; the anode layer may contain an insoluble conductive material such as platinum group metals and their associated oxides, highly doped semiconducting materials, and carbon based conductors. The anode layer may be deposited using chemical vapor deposition or physical vapor deposition. Alternatively in one or more embodiments the printhead may be constructed by manufacturing a separate anode plane component, and then bonding the anode plane to the backplane.

Methods of additive manufacturing are described herein. In one aspect, a method of printing an article comprises (a) selectively depositing an initial layer of transition metal or transition metal oxide on a substrate, and (b) at least partially replacing the initial layer of transition metal or transition metal oxide with a noble metal layer via a galvanic replacement reaction. In step (c), an additional layer of transition metal or transition metal oxide is deposited on the noble metal layer, and in step (d), the additional layer of transition metal or transition metal oxide is at least partially replaced with an additional noble metal layer via a galvanic replacement reaction. Steps (c) and (d) are repeated until the article is completed. In some embodiments, the article is subsequently separated from the substrate and can be coupled to a secondary substrate.

Process for manufacturing a printhead for a 3D manufacturing system that uses metal electrodeposition to construct parts. The printhead may be constructed by depositing layers on top of a backplane that contains control and power circuits. Deposited layers may include insulating layers and an anode layer that contain deposition anodes that are in contact with the electrolyte to drive electrodeposition. Insulating layers may for example be constructed of silicon nitride or silicon dioxide; the anode layer may contain an insoluble conductive material such as platinum group metals and their associated oxides, highly doped semiconducting materials, and carbon based conductors. The anode layer may be deposited using chemical vapor deposition or physical vapor deposition. Alternatively in one or more embodiments the printhead may be constructed by manufacturing a separate anode plane component, and then bonding the anode plane to the backplane.

A method of additive manufacturing that deposits material onto a cathode by transmitting current from an anode array through an electrolyte to the cathode; the method uses feedback to control the manufacturing of successive layers of a part. For example, feedback signals may be a map of current across the anode array; this current map may be processed using morphological analysis or Boolean operations to determine the extent of deposition across the layer. Feedback data may be used to determine when a layer is complete, and to adjust process parameters such as currents and voltages during layer construction. Layer descriptions may be preprocessed to generate maps of desired anode current, to manipulate material density, and to manage features such as overhangs. Feedback signals may also trigger execution of maintenance actions during the build, such as replenishment of anodes or removal of films or bubbles.

A method of additive manufacturing that deposits material onto a cathode by transmitting current from an anode array through an electrolyte to the cathode; the method uses feedback to control the manufacturing of successive layers of a part. For example, feedback signals may be a map of current across the anode array; this current map may be processed using morphological analysis or Boolean operations to determine the extent of deposition across the layer. Feedback data may be used to determine when a layer is complete, and to adjust process parameters such as currents and voltages during layer construction. Layer descriptions may be preprocessed to generate maps of desired anode current, to manipulate material density, and to manage features such as overhangs. Feedback signals may also trigger execution of maintenance actions during the build, such as replenishment of anodes or removal of films or bubbles.

Embodiments are directed to fuel injectors for internal combustion engines (e.g. engines with reciprocating pistons and with compression-ignition or spark-ignition, Wankel engines, turbines, jets, rockets, and the like) and more particularly to improved nozzle configurations for use as part of such fuel injectors. Other embodiments are directed to enabling fabrication technology that can provide for formation of nozzles with complex configurations and particularly for technologies that form structures via multiple layers of selectively deposited material or in combination with fabrication from a plurality of layers where critical layers are planarized before attaching additional layers thereto or forming additional layers thereon. Other embodiments are directed to methods and apparatus for integrating such nozzles with injector bodies.

A system and method of using electrochemical additive manufacturing to add interconnection features, such as wafer bumps or pillars, or similar structures like heatsinks, to a plate such as a silicon wafer. The plate may be coupled to a cathode, and material for the features may be deposited onto the plate by transmitting current from an anode array through an electrolyte to the cathode. Position actuators and sensors may control the position and orientation of the plate and the anode array to place features in precise positions. Use of electrochemical additive manufacturing may enable construction of features that cannot be created using current photoresist-based methods. For example, pillars may be taller and more closely spaced, with heights of 200 m or more, diameters of 10 m or below, and inter-pillar spacing below 20 m. Features may also extend horizontally instead of only vertically, enabling routing of interconnections to desired locations.

A method of forming a component by an electroforming process using an electroforming apparatus is presented. The electroforming apparatus includes an anode, a cathode and an electrolyte including a metal salt. The method includes receiving a set of training electroforming process parameters; training a machine learning algorithm based on at least a subset of the set of training electroforming process parameters; generating a set of updated operating electroforming parameters from the trained machine learning algorithm; and operating the electroforming apparatus based on the set of updated operating electroforming parameters. The step of operating the electroforming apparatus includes applying an electric current between the anode and the cathode in the presence of the electrolyte and depositing a plurality of metal layers on a cathode surface to form the component. A system of forming a component is also presented.