Investigating the Potential of Electroless Nickel Plating for Fabricating Ultra-Porous Metal-Based Lattice Structures Using PolyHIPE Templates

The use of polymerized high internal phase emulsions(polyHIPEs)as templates for electroless nickel plating is a promising methodfor producing ultra-porous metallic lattice structures with consistentwall thickness. These structures have desirable properties such aslow density, high specific strength, resilience, and absorbency, makingthem suitable for various applications including battery electrodes,catalyst supports, and acoustic or vibration damping. This study aimedto optimize and investigate the electroless nickel plating processon polyHIPEs. Initially, a surfactant (Hypermer)-stabilized water-in-oilemulsion based on 2-ethylhexyl-acrylate and isobornyl-acrylate wasused as a 3D printing resin to create polyHIPE structures. Then, theelectroless nickel plating process was optimized using polyHIPE discs.The study also examined the effects of air, argon, and reducing atmospheresduring the heating process to remove the polyHIPE template using metallized3D-printed polyHIPE lattice structures. The findings indicated thatdifferent atmospheres led to the formation of distinct compounds.While nickel-coated polyHIPEs were fully oxidized in an air atmosphere,nickel phosphide (Ni3P) structures occurred in argon andreducing atmospheres along Ni metal. Moreover, in argon and reducingatmospheres, the porous structure of the polyHIPEs was retained asthe internal structure was completely carbonized. Overall, the studydemonstrated that intricate polyHIPE structures can be used as templatesto create ultra-porous metal-based lattices for a wide range of applications.

Automated summary

The use of polymerized high internal phase emulsions (polyHIPEs) as templates for electroless nickel plating enables the production of ultra-porous metallic lattice structures with consistent wall thickness. These structures have desirable properties and can be used in various applications. This study optimized the electroless nickel plating process on polyHIPEs and examined different atmospheres during the heating process to remove the polyHIPE template. The findings showed that distinct compounds were formed under different atmospheres, and the porous structure of polyHIPEs was retained in certain conditions.