Selective electroplating of 3D printed parts

Fused filament fabrication (FFF) 3D printers have been largely limited to thermoplastics in the past but with new composite materials available on the market there are new possibilities for what these machines can produce. Using a conductive composite filament, electronic components can be manufactured but due to the filament's relatively poor electrical properties, the resulting traces are typically highly resistive. Selective electroplating on these parts is one approach to incorporate materials with high conductivity onto 3D-printed structures. In this paper, non-conductive and conductive filaments printed in the same part are used to enable selective electroplating directly on regions defined by the conductive filament to create metallic parts through 3D printing. This technique is demonstrated for the creation of multiple distinct conductive segments and to electroplate the same part with multiple metals to, for instance, allow a magnetic metal such as nickel and a highly conductive one such as copper to be incorporated in the same part. Following the characterization of the process, a representative 3D printed electrical device, a selectively electroplated solenoid inductor with low frequency inductance and resistance of 191 nH and 18.7 mΩ respectively was manufactured using this technique. This is a five order of magnitude reduction in resistance over the original value of 3 kΩ for the inductor before electroplating.