EDM electrode manufacturing using RP combining electroless plating with electroforming

This study investigates an effective method for manufacturing electrical discharge machining (EDM) electrodes using the rapid prototyping (RP) system based on electroless plating (nickel plating) and electroforming (copper). This method was shown to finish the development of die-sinking electrical discharge machining (EDM) electrodes, shorten the electrode manufacturing process, decrease the manufacturing duration as well as the cost of electrodes. The electrode prototype was drawn with Pro/E 3D CAD, and the CAD model was then transformed into the stereo lithography (STL) file format. A Zcorp 402 3DP rapid prototyping machine was adopted to make a gypsum powder electrode prototype with a complex appearance. The gypsum material is sealed by resin permeation, enhancing its water-resistance and strength. Electroless plating was then performed to introduce electric conductivity onto the gypsum electrode surface, followed by copper electroforming of the thickness about 1 mm to obtain the EDM electrode. Furthermore, die-sinking electric discharge machining was performed. Test results indicate that no crack was found on the electrode and that the electrical discharge machining effects are promising.