The study of an image feedback-assisted jet electrochemical additive manufacturing process

Abstract

Jet electrochemical deposition (Jet ECD) has attracted increasing attention for its high deposition rate. However, the electrochemical deposition rate exhibits pronounced nonlinear characteristics over time, making it difficult to precisely control the growth of 3D structures. In the present study, an image-based monitoring and feedback mechanism is proposed and validated. This method utilizes a high-magnification camera to capture real-time images of the deposition zone. Through an image recognition algorithm, it identifies the contact state between the printed copper column and the liquid column. It then dynamically generates displacement control commands and enables precise regulation of deposition time and position. Moreover, it facilitates analysis of the nonlinear deposition rate during deposition. Experimental results demonstrate that this method effectively accommodates the nonlinear behavior inherent in the deposition process. It enables the successful fabrication of overhanging structures with angles ranging from 0° to 80°, exhibiting favorable morphology and high density. Additionally, the fabrication of helical multi-segment structures and trifurcated branch structures validates the method's applicability and scalability for manufacturing complex multi-directional 3D structures. This study provides a novel strategy for realizing closed-loop control in electrochemical additive manufacturing (ECAM) and lays a technical foundation for constructing high-precision, complex 3D structures.