Creating Complex Hollow Metal Geometries using Additive Manufacturing and Electroforming

Additive manufacturing introduces a new design paradigm that allows the fabrication of geometrically complex parts that cannot be produced by traditional manufacturing and assembly methods. In this paper, the authors investigate the combination of laser sintering with an electroforming process using electroless nickel plating to produce complex, thin-walled, hollow, metal geometries. The resulting geometries cannot be produced directly with other additive manufacturing systems. The resulting process is used to produce a cellular nickel structure featuring 800µm walls that is 65 vol% air from a polyamide substrate with 3mm pores.