Advances in Manufacturing

, Volume 6, Issue 4, pp 442–456 | Cite as

Performance analysis of a thick copper-electroplated FDM ABS plastic rapid tool EDM electrode

  • Saroj Kumar PadhiEmail author
  • S. S. Mahapatra
  • Rosalin Padhi
  • Harish Chandra Das


The importance of rapid tooling (RT) and additive manufacturing (AM) appears to be indispensable for boosting the process of manufacturing and expanding the horizon of production technology worldwide. This concept draws the attention of numerous scholars to arrive at a conclusive theory for the widespread utilization of RT. This study attempts to determine the viability and performance of an RT electrode in the field of electro discharge machining (EDM). The electrode prototype is made using an acrylonitrile butadiene styrene (ABS) plastic by fused deposition modeling (FDM), an AM technique, electroplated with copper of desired thickness, and used in die sinking EDM of D2 steel. The scanning electron microscope analysis of the electroplated samples confirms that it is possible to obtain the desired thickness of the metal by electroplating on any electrically conductive surface. In the present work, an experimental study is performed for examining the electroplated copper thickness of the plastic EDM electrode and its performances. It is found that the electroplated ABS plastic EDM RT electrode successfully performs the machining operation of D2 steel, and the results are comparable with a solid electrode. The study reveals that the RT electrode can be regarded as a viable tool for rough cutting or semi-finishing cut EDM functions. The experimental results are thoroughly discussed, examined, analyzed, and evaluated for the purpose of developing the appropriate form of the concept.


Additive manufacturing (AM) Fused deposition modeling (FDM) Metallization of acrylonitrile butadiene styrene (ABS) plastic Reduced silver colloidal Rapid tooling (RT) Electro discharge machining (EDM) 


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Copyright information

© Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature 2018

Authors and Affiliations

  • Saroj Kumar Padhi
    • 1
    Email author
  • S. S. Mahapatra
    • 2
  • Rosalin Padhi
    • 3
  • Harish Chandra Das
    • 4
  1. 1.Department of Mechanical Engineering, Koneru Lakshmiah Education FoundationDeemed to be UniversityVaddeswarmIndia
  2. 2.Department of Mechanical EngineeringNational Institute of Technology RourkelaRourkelaIndia
  3. 3.Department of PhysicsBerhampur UniversityBerhampurIndia
  4. 4.Department of Mechanical EngineeringNational Institute of Technology MeghalayaShillongIndia

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