Electrochemical 3D printing of copper/graphene composites with gel precursors

Journal article, 2025

The fusion of fashion-inspired designs with metal component production represents a significant transformation across various industries, seamlessly integrating design with functionality. While metal Additive Manufacturing (AM) has redefined the creation of customized 3D items, it encounters barriers in achieving a wider adoption due to the high investment cost. Conversely, Electrochemical Additive Manufacturing (ECAM) emerges as a promising alternative, offering cost-effectiveness and precision in fabricating metal microstructures through precise material deposition, reducing raw material waste and enabling intricate patterns without requiring expensive tooling or molds. Despite the valued properties of copper microstructures in many technological domains, their tendency to corrosion remains a severe problem. It's important to manager copper corrosion risks for preserving their functionality and durability. Copper/Graphene (Cu/Gr) composites have garnered attention for their enhanced mechanical, electrical, and thermal stability, rendering them suitable for diverse applications while also improving their anti-corrosion behavior. Herein, we explored an economical and sustainable approach to printing homogeneous Cu/Gr nanocomposites (8 mm length) using desktop ECAM coupled with cellulose-based gels as precursors. Compositional, morphological characteristics, and corrosion resistance were examined to assess their potential as electronic manufacturing components. Our findings will provide new printing strategies for metal-based nanocomposites derived from metal salts and graphene additives in aqueous solution, while also addressing the corrosion prevention to maintain the integrity and functionality of copper-based microdevices.