FDM Technology for EDM Electrode Fabrication: Progress, Prospects, and Perspectives

This comprehensive review delves into the applicability of Fused Deposition Modeling (FDM) in Electrical Discharge Machining (EDM) electrode fabrication, scrutinizing its potential, challenges, and recent advancements. The review elucidates the advantages of FDM, including rapid prototyping, design flexibility, and cost-effectiveness, while examining its limitations, such as surface finish and material selection. Various metallization methods for enhancing the conductivity of FDM-generated electrodes are explored, ranging from electroless plating to vacuum metalizing. Comparative analyses with traditional manufacturing methods like milling, grinding, and wire EDM provide valuable insights into the efficacy of FDM. Additionally, the review discusses real-world applications across industries, highlighting aerospace, automotive, medical, and tooling sectors. Emerging trends, challenges, and future directions in FDM technology for EDM electrode fabrication are thoroughly examined, emphasizing the need for ongoing research and innovation to realize the full potential of FDM in modern manufacturing.