The electrochemical metallization of polymer lattice structures offers a promising approach for the production of functionalized components, e.g. for lightweight purposes. Especially in the case of stochastic lattice structures with a high surface-to-volume ratio, the surface coating leads to considerable fractions of the deposited metal. Long deposition times require consideration of the non-uniform layer thickness distribution induced by electrochemical effects. This process-induced grading of the strut thickness can improve the mechanical load-bearing capacity of the component in bending and torsion, as more material is deposited in the outer areas. However, efficient load introduction remains critical. In this study, different concepts for load transfer are developed, experimentally investigated and compared. Recommendations are given for the design of mechanically stressed functional surfaces of electrochemically metallized polymer lattice structures. The main results emphasize that the outermost struts for positive connections should be oriented perpendicular to the surface and that pre-inserted metal thread inserts improve both the connectivity to external systems and the mechanical load-bearing capacity of the component. While the use of copper coatings in this study demonstrates the feasibility of the approach, copper is not ideal for lightweight applications due to its high density and unfavorable density-to-stiffness ratio. Future work should therefore explore alternative electroplated materials such as high-strength nickel-based alloys, which offer superior specific stiffness and can unlock significantly higher lightweight potential.

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Load Introduction in Electrochemically Metallized Polymer Lattice Structures: Experimental Evaluation of Interface Design Concepts

  • Marco Noack,
  • Thomas Schmidt,
  • Eckhard Kirchner

摘要

The electrochemical metallization of polymer lattice structures offers a promising approach for the production of functionalized components, e.g. for lightweight purposes. Especially in the case of stochastic lattice structures with a high surface-to-volume ratio, the surface coating leads to considerable fractions of the deposited metal. Long deposition times require consideration of the non-uniform layer thickness distribution induced by electrochemical effects. This process-induced grading of the strut thickness can improve the mechanical load-bearing capacity of the component in bending and torsion, as more material is deposited in the outer areas. However, efficient load introduction remains critical. In this study, different concepts for load transfer are developed, experimentally investigated and compared. Recommendations are given for the design of mechanically stressed functional surfaces of electrochemically metallized polymer lattice structures. The main results emphasize that the outermost struts for positive connections should be oriented perpendicular to the surface and that pre-inserted metal thread inserts improve both the connectivity to external systems and the mechanical load-bearing capacity of the component. While the use of copper coatings in this study demonstrates the feasibility of the approach, copper is not ideal for lightweight applications due to its high density and unfavorable density-to-stiffness ratio. Future work should therefore explore alternative electroplated materials such as high-strength nickel-based alloys, which offer superior specific stiffness and can unlock significantly higher lightweight potential.