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Purpose: Selective jet electrodeposition (SJED) is an emerging additive manufacturing (AM) technology for realizing metallic components of nano and micro sizes. The deposited parts on the substrate form metallurgical bonding, so separating them from the substrate is an unsolved issue. Therefore, this paper aims to propose a method for separating the deposited micro parts from a sacrificial substrate. Furthermore, single and multi-bead optimization is performed to fabricate microparts with varying density. Design/methodology/approach: A typical SJED process consists of a nozzle (to establish a column of electrolytes) retrofitted on a machine tool (to provide relative motion between substrate and nozzle) that deposits material atom-by-atom on a conductive substrate. Findings: A comprehensive study of process parameters affecting the layer height, layer width and morphology of the deposited micro-parts has been provided. The uniformity in the deposited parts can be achieved with the help of low applied voltage and high scanning speed. Multi-bead analysis for the flat surface condition is experimentally performed, and the flat surface condition is achieved when the centre distance between two adjacent beads is kept at half of the width of a single bead. Originality/value: Although several literatures have demonstrated that the SJED process can be used for the fabrication of parts; however, part fabrication through multi-bead optimization is limited. Moreover, the removal of the fabricated part from the substrate is the novelty of the current work. [ABSTRACT FROM AUTHOR]

Selective Jet Electrodeposition (SJED) emerges as a cutting-edge Additive Manufacturing technology, offering the ability to produce metallic components at both nano and micro scales. In SJED, metallic deposition occurs atom by atom, showcasing potential applications for electroplating (coating) purposes. Achieving a smooth and void-free coating necessitates optimisation of layer height, width and the centre distance between two adjacent beads. An ANOVA study is performed to identify the most impactful input process parameters among source voltage, scan speed and frequency. It evaluates their contribution to the output responses (layer height and width). Furthermore, Response Surface Methodology is performed to obtain the optimal parameters to achieve maximum layer height and minimum layer width. Additionally, multi-bead optimisation is performed to achieve a flat surface condition. Subsequently, a coating is carried out using a toolpath, and a comparative analysis is conducted with the conventional coating method in terms of mechanical properties. The SJED-based coating exhibits superior characteristics compared to conventional coating. [ABSTRACT FROM AUTHOR]