Lost Core Nanomaterial Electroforming Process (LCNE) for the Low-Cost Manufacture of Complex High-Strength, Lightweight, High Temperature Service Components

Advancements in low-cost polymer additive manufacturing and electroforming of high-strength, thermally stable nanostructured metal alloys have enabled a novel, efficient, and cost-effective Lost Core Nanomaterial Electroforming Process (LCNE). This process is ideally suited for manufacturing complex, high-performance components designed for high-temperature applications across a wide range of industries, including aerospace, defense, and energy.

The LCNE process combines additive manufacturing of intricate polymer cores with electroforming of nanostructured alloys, allowing for the creation of lightweight, durable, and geometrically complex parts that can withstand high temperatures and harsh environments. This approach is especially beneficial for producing intricate components such as heat exchangers, turbine housings, manifolds, and other high-temperature ducting systems where conventional manufacturing techniques fall short.

This presentation will provide an overview of the key process steps, including core fabrication, electroforming, and core removal (if required), as well as a discussion of the unique properties of the nanostructured alloys used. The enhanced mechanical strength, thermal stability, and corrosion resistance of these materials make them ideal for demanding applications that require both performance and cost-efficiency.