Rapid prototyping manufacturing (RPM) has received high interest in the field of engineering. However,the current processing methods are complex and expensive, and it is difficult to prepare nanostructurematerials, which limits further applications. Electrolyte jet machining is an emerging precisionmanufacturing technology that uses an electrolyte jet to generate a metallic deposit with a high depositionrate and a nanocrystalline material structure. This paper is devoted to developing a new type ofprototyping technology that employs electrolyte jet machining to form a micro-metallic part with ananocrystalline material. The new manufacturing method is expected to cover the shortcomings of thecurrent RPM technology. The concept of incorporating electrolyte jet machining and rapid prototypingtechnology as well as an experimental practice are introduced. It is believed that the forming precisionof electrolyte jet machining is determined by process localization, which is mainly influenced by thetechnical parameters, including the nozzle diameter, jet distance, current density, and nozzle scan speed.The technical parameters are studied regarding their effects on the process localization. It is proven thatthe application of a small nozzle diameter, low current density and fast scan speed is highly favourablefor reducing the size of the electroformed spot and for improving process localization. A group ofnanocrystalline copper parts with a good shape have been produced using optimized parameters.
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