Sustainable direct metallization of 3D-printed metal-infused polymer parts: a novel green approach to direct copper electroless plating

Javid Sharifi; Vlad Paserin; Haniyeh (Ramona) Fayazfar

doi:10.1007/s40436-024-00486-0

Advances in Manufacturing ›› : 1 -14. DOI: 10.1007/s40436-024-00486-0

Article

Sustainable direct metallization of 3D-printed metal-infused polymer parts: a novel green approach to direct copper electroless plating

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¹ Eco-friendly Center of Circular Advanced Materials and Additive Manufacturing, Department of Mechanical and Manufacturing Engineering, Ontario Tech University, L1G 0C5, Oshawa, Ontario, Canada

² VPM Research Inc, Mississauga, Ontario, Canada

^c ramona.fayazfar@ontariotechu.ca

Javid Sharifi is a Ph.D. student (Starting Sept. 2021) from the Ontario Tech University, Department of Mechanical and Manufacturing Engineering, Ontario, Canada. He has 4+ years of expertise in developing multifunctional composite materials, nano biosensors, and 3D printing, along with surface engineering. He is currently working on surface engineering and development and optimization of novel additive manufacturing (AM)-specific categories and materials to address current challenges of additive manufacturing in the Eco-Friendly Center of Circular Advanced Materials and Additive Manufacturing (E-CAM) group.

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Vlad Paserin has 29 years of industrial R&D experience working at Vale Canada (previously Inco Limited, 1988-2014) and Rio Tinto Metal Powders (2015-18). He specializes in vapometallurgy of nickel and iron and in the development and production of metal powders and metal foams. He is the author of several patents and publications in the area of metal foams, chemical vapor deposition and nanomaterials. As of 2018, he works as a consultant and Principal at VPM Research Inc. and is an Adjunct Assistant Professor at the University of Waterloo (Mechanical Engineering) and Research Associate (Chemical Engineering). He holds a PhD degree in Physics from University of Waterloo, Ontario, Canada and has a “Professional Physicist” designation as a member of the Canadian Association of Physicists.

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Haniyeh (Ramona) Fayazfar is an Assistant Professor at the Department of Mechanical and Manufacturing Engineering at Ontario Tech University. She is the director of the Eco-Friendly Center of Circular Advanced Materials and Additive Manufacturing (E-CAM). She holds an affiliate associate graduate faculty appointment in Materials Science. Dr. Fayazfar holds a Ph.D., MS.C., and B.S.C. with high honors in Material Science and Engineering from the Sharif University of Technology. Before joining Ontario Tech, she was a postdoctoral fellow in the Multi-Scale Additive Manufacturing group at the University of Waterloo. She has over 20 years of experience in advanced materials, additive manufacturing, sustainable (nano) materials, electrochemistry, and surface engineering. Her current research in her group concentrates on additive manufacturing (metals, polymers, ceramics, composites), bio Augmentation of circular and carbon-negative materials, sustainable and recyclable materials for 3D printing, biomass-filled biodegradable/recyclable polymeric composites, surface engineering, and advanced coatings, as well as sensors and wearables for point-of-care diagnostics and health monitoring. She has been awarded the “Best Research Award” for Innovative Development of Nanocomposite Materials as a High Sensitive Biosensor to Detect Cancer, presented by the International Research Awards on New Science Inventions 2021. Her research contributions have been recognized by Best Paper/Presentation awards at international materials, manufacturing, and engineering education conferences. She is also a recipient of the First Place Award in recognition of being ranked first among MS.C. and Ph.D. graduates in the Department of Materials Science and Engineering at the Sharif University of Technology.

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Abstract

Metallization, which is coating metals on the surface of objects, has opened up new possibilities for lightweight structures while integrating polymer and metal features. Electroless plating is a potential method for metalizing plastic 3D-printed parts; however, conventional approaches rely on pre-surface activation and catalyzation with expensive metal catalysts and hazardous acids. To address these issues, the current study represents a novel eco-friendly and low-cost approach for direct metallization of non-conductive 3D-printed parts, without using hazardous, toxic, and expensive conventional pre-treatments. Using the developed methodology, we electrolessly copper plated polymer-copper infused 3D-printed part as well as plastic components for the first time, directly. We initiated and implemented the idea of exposing the copper particles embedded in the polymer to the surface of copper-polymer parts by applying a sustainable mechanical or chemical method to make the surface conductive and ready for direct plating. A formaldehyde-free (green) electroless copper solution was developed in-house in addition to skipping conventional etching pre-treatment using harmful chemicals, making this a real step forward in the sustainable metallization of 3D-printed parts. In this study, the mechanical properties of copper-polylactic acid (PLA) 3D-printed parts revealed a 65% reduction in tensile strength and 63% increase in tensile modulus, compared to virgin PLA. Furthermore, the morphological characterization of the copper coated 3D-printed parts showed a homogeneous copper coating on the surface after direct electroless plating, with a plating rate of 7.5 μm/h. Allowing complex and functional devices printed in this manner to be quickly metalized without modification using toxic and costly solutions is a significant advancement in lowering the cost and manufacturing complexity of 3D-printed parts, increasing efficiencies, and lowering weight, and thus is a game changer in the technology’s adoption.

Keywords

Material extrusion / Additive manufacturing (AM) / Copper-polymer filaments / Electroless plating / Sustainability / Metallization

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Javid Sharifi,Vlad Paserin,Haniyeh (Ramona) Fayazfar. Sustainable direct metallization of 3D-printed metal-infused polymer parts: a novel green approach to direct copper electroless plating. Advances in Manufacturing 1-14 DOI:10.1007/s40436-024-00486-0