US 12,264,405 B2
Methods for electrochemical additive manufacturing while modifying electrolyte solutions
David Pain, San Diego, CA (US); Jeffrey Herman, San Diego, CA (US); Kareemullah Shaik, San Diego, CA (US); and Andrew Edmonds, San Diego, CA (US)
Assigned to Fabric8Labs, Inc., San Diego, CA (US)
Filed by Fabric8Labs, Inc., San Diego, CA (US)
Filed on Aug. 30, 2022, as Appl. No. 17/823,227.
Claims priority of provisional application 63/246,152, filed on Sep. 20, 2021.
Prior Publication US 2023/0089135 A1, Mar. 23, 2023
Int. Cl. C25D 1/00 (2006.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01)
CPC C25D 1/003 (2013.01) [B33Y 10/00 (2014.12); B33Y 30/00 (2014.12)] 20 Claims
OG exemplary drawing
 
1. A method of electrochemical additive manufacturing using an electrochemical additive manufacturing system comprising an electrodeposition cell formed by an electrode array and a deposition electrode, the method comprising:
flowing an electrolyte solution into and through a gap formed by the electrode array, comprising individually-addressable electrode portions, and the deposition electrode, wherein:
the individually-addressable electrode portions are arranged in a two-dimensional grid defined by an electrode array plane,
the electrolyte solution enters the gap through an inlet and exits the gap through an outlet, and
the inlet is separated from the outlet by the two-dimensional grid such that the electrolyte solution flows through the gap in a direction substantially parallel to the electrode array plane while contacting the individually-addressable electrode portions;
depositing a target material onto the deposition electrode from the electrolyte solution by flowing a current between a subset of the individually-addressable electrode portions of the electrode array in a direction substantially perpendicular to the electrolyte solution flow onto the deposition electrode, operating as a cathode, wherein the subset of the individually-addressable electrode portions is selected based on a desired location of the target material on the deposition electrode,
measuring one or more characteristics of the electrolyte solution thereby producing one or more measured values, wherein the one or more characteristics comprise a current through the electrolyte solution; and
changing the one or more characteristics of the electrolyte solution within the electrochemical additive manufacturing system using one or more electrolyte-altering devices, wherein:
the one or more characteristics of the electrolyte solution, which are changed, comprise one or more of an acid concentration, a feedstock ion concentration, and a plating additive concentration, and
the one or more characteristics of the electrolyte solution are changed based on the one or more measured values.