Feasibility study of fusible alloy-based copper electroplated EDM tool for biomedical applications

Abstract

The current study demonstrates the idea of making customised EDM tools using low melting point alloys for possible application in surface modification of biomedical implants. The mould is 3D-printed through a selective laser sintering setup and is used for casting the eutectic tin bismuth alloy. The mould is 3D scanned before and after using it as a mould for inspecting dimensional accuracy. The mould and cast pattern are measured for their surface roughness. The electroplating setup is developed, plating parameters are identified for stable copper deposits on a cast pattern, and thickness is noted with time. The scanning electron microscope analyses the microstructure of the casted and plated sample. The X-ray diffraction test and energy dispersive spectroscopy verify their composition. The plated sample is used as an electrical discharge machining tool. The planned experiments are performed, and Taguchi optimisation is carried out. The rapid cast tool performance is comparable to the solid copper tool. The valuable insights are drawn out after analysing the results, and the mechanism is explained. The previous research work done in this regard consists of the polymer base material with subsequent primary and secondary metallisation. However, the current study utilised the conductive base material, which eliminates the need for primary metallisation. The current work's application is defined in terms of creating a free-form EDM tool for surface modification of the Ti–6Al–4V femur bone implant for better cell growth.