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<p>In a world striving for carbon neutrality and sustainable resource management, repairing components rather than replacing them is increasingly vital. This study presents an innovative, low‑cost, and energy‑efficient electrodeposition additive manufacturing (EDAM) system for precise repair. In contrast with conventional methods involving high temperatures, limited control, and hazardous emissions, our approach employs low‑temperature electrochemical deposition to achieve high‑precision, localized repairs with a high‑voltage‑enhanced deposition rate using an eco‑friendly glycerol‑based electrolyte (G‑EDAM). A control system enabling on‑the‑fly EDAM is developed, achieving consistent copper deposition on brass substrates. The system maintains current stability, localized deposition accuracy, and electrode intactness under voltages exceeding the water‑splitting potential. To compare G‑EDAM with the widely used water‑based recipe (W‑EDAM) and identify the source of its performance advantages, a novel electrochemical‑fluidic observation was performed. Quantitatively, G-EDAM maintains a stable deposition current of ~ 0.02 A for 1500&#xa0;s, whereas W-EDAM exhibits a rapid current decay from ~ 0.11 A to ~ 0 A within ~ 300&#xa0;s and fails mechanically within ~ 2&#xa0;min. Based on the case study, G-EDAM tool continues stable operation for at least 20&#xa0;min. G-EDAM confines the deposited track to ~ 3&#xa0;mm, compared to a stray-current-affected width of ~ 8&#xa0;mm in W-EDAM (&gt; 100% larger), and produces a more uniform step-height evolution with reduced roughness fluctuations over time. Superior G‑EDAM performance is attributed to the higher viscosity of glycerol electrolyte, which governs bubble nucleation, growth, and detachment at such a voltage, modulates local electric fields, and suppresses electrolyte’s morphological instabilities. This synergistic control of electric‑field distribution and mass transport underlie the uniform, defect-free films achieved in G‑EDAM. The G-EDAM design provides a sustainable, scalable, and cost‑effective solution for industrial applications, aligning with modern environmental and manufacturing priorities.</p>

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Exploring Feasibility of Location-Selective Stable Electrodeposition Additive Manufacturing (EDAM) at a Voltage Passing Water Splitting

  • 期刊论文

  • 发表日期：

    2026年1月6日

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  • Toushiqul Islam,
  • Declan Picot,
  • Shiqi Ma,
  • Xiaowei He,
  • Shuaihang Pan

摘要

In a world striving for carbon neutrality and sustainable resource management, repairing components rather than replacing them is increasingly vital. This study presents an innovative, low‑cost, and energy‑efficient electrodeposition additive manufacturing (EDAM) system for precise repair. In contrast with conventional methods involving high temperatures, limited control, and hazardous emissions, our approach employs low‑temperature electrochemical deposition to achieve high‑precision, localized repairs with a high‑voltage‑enhanced deposition rate using an eco‑friendly glycerol‑based electrolyte (G‑EDAM). A control system enabling on‑the‑fly EDAM is developed, achieving consistent copper deposition on brass substrates. The system maintains current stability, localized deposition accuracy, and electrode intactness under voltages exceeding the water‑splitting potential. To compare G‑EDAM with the widely used water‑based recipe (W‑EDAM) and identify the source of its performance advantages, a novel electrochemical‑fluidic observation was performed. Quantitatively, G-EDAM maintains a stable deposition current of ~ 0.02 A for 1500 s, whereas W-EDAM exhibits a rapid current decay from ~ 0.11 A to ~ 0 A within ~ 300 s and fails mechanically within ~ 2 min. Based on the case study, G-EDAM tool continues stable operation for at least 20 min. G-EDAM confines the deposited track to ~ 3 mm, compared to a stray-current-affected width of ~ 8 mm in W-EDAM (> 100% larger), and produces a more uniform step-height evolution with reduced roughness fluctuations over time. Superior G‑EDAM performance is attributed to the higher viscosity of glycerol electrolyte, which governs bubble nucleation, growth, and detachment at such a voltage, modulates local electric fields, and suppresses electrolyte’s morphological instabilities. This synergistic control of electric‑field distribution and mass transport underlie the uniform, defect-free films achieved in G‑EDAM. The G-EDAM design provides a sustainable, scalable, and cost‑effective solution for industrial applications, aligning with modern environmental and manufacturing priorities.