Materials and Processes for Additive Manufacturing of Nonporous and Chemically-Resistant Masks for Electroplating with COTS 3D Printers

U.S. Air Force maintenance activities need a cost effective, rapidly manufacturable, multi-use masking system for electroplating aerospace components. The masks must be nonporous, and resistant to highly corrosive aqueous solutions at elevated temperature. Additive manufacturing is a superb tool for rapidly manufacturing low-run highly customized parts, precisely what is required, but porosity is a problem. Intelligent Optical Systems, Inc. has developed a process to 3D print nonporous parts, which have proven to be watertight, using commercial off-the-shelf (COTS) printers. We will apply this process to commercially available advanced engineering materials that can withstand the harsh chemicals used in electroplating at elevated temperatures, and will meet all the solicitation requirements using only COTS 3D printers. Proof-of-concept prototypes will be produced to demonstrate conformance to the requirements, firmly establishing the technical feasibility of 3D printed masks for electroplating. Successful execution of the proposed work will result in a process to rapidly manufacture high-quality functional 3D printed masks that have the chemical and thermal stability, and physical properties, required for electroplating. We will also conduct a business case analysis to determine implementation costs, including a return-on-investment calculation that compares anticipated savings to expected costs.