Development and performance evaluation of flexible graphene-copper composites via laser-induced graphene and electrodeposition for electrochemical machining cathodes

Electrochemical machining (ECM) is widely used in industries such as aerospace and MEMS, but it faces challenges in precise and localized machining of curved surfaces due to the need for customized cathode tools and masking, which increase both costs and development time. This study presents a novel approach for fabricating flexible graphene-copper composites (GCC) as cathodes for ECM. The composites are synthesized using laser-induced graphene (LIG) technology on polyimide (PI) substrates followed by copper electrodeposition. The resulting GCC exhibit outstanding localization, electrical conductivity, flexibility, and corrosion resistance, demonstrating their potential for use as flexible cathodes in ECM applications. The impact of laser scanning speed on LIG formation is investigated, and optimized parameters yield high-quality LIG regions. Various electrodeposition conditions, including applied voltage, deposition time, and stirring, are analyzed for their effect on the properties of the GCC. The composition, formation mechanisms, and corrosion resistance of the GCC are evaluated. Using these GCC cathodes, quasi-square and concave circular shapes are successfully etched on stainless steel, with smoother surfaces observed in the central electrolytic regions. After 30 min of etching, the GCC maintain their original structure, showing good durability. This study highlights the strong potential of flexible GCC as cathode materials for ECM, offering a promising avenue for future research and application in precision machining.