Methods of forming electroformed components and related system

A method of forming a component by an electroforming process using an electroforming apparatus comprising an anode, a cathode and an electrolyte comprising a metal salt, the method comprising:

• receiving a set of training electroforming process parameters, the set of training electroforming process parameters including one or more of first coordinates of a shield, a first orientation state of the shield, second coordinates of an auxiliary electrode, a second orientation state of the auxiliary electrode, or a waveform characteristic of an applied electric current;
• training, based on at least one simulated electroforming process, a machine learning algorithm based on at least a first subset of the set of training electroforming process parameters;
• validating the machine learning algorithm based on a second subset of the set of training electroforming process parameters corresponding to the at least one simulated electroforming process;
• generating a set of updated operating electroforming parameters from at least one of the training or the validating, wherein the set of updated operating parameters comprises one or more of first updated coordinates of the shield, a first updated orientation state of the shield, second updated coordinates of the auxiliary electrode, a second updated orientation state of the auxiliary electrode, or an updated waveform characteristic of the applied electric current;
• and
• operating an electroforming apparatus based on the set of updated operating electroforming parameters, wherein operating the electroforming apparatus comprises:
• moving, using a robotic assembly, the anode, based on the set of updated operating electroforming parameters,
• applying the applied electric current between the anode and the cathode in a presence of the electrolyte, after each movement of the anode, and
• depositing a plurality of metal layers on a surface of the cathode to form the component.

A system for electroforming a component, the system comprising:

• an electroforming apparatus comprising an anode, a cathode, and an electrolyte comprising a metal salt;
• and
• a controller operatively coupled to the electroforming apparatus, the controller comprising:
• a memory storing one or more processor-executable routines and a machine learning algorithm;
• and
• one or more processors to execute the one or more processor-executable routines which, when executed, cause acts to be performed comprising:
• receiving a set of training electroforming process parameters, the set of training electroforming process parameters including one or more of first coordinates of a shield, a first orientation state of the shield, second coordinates of an auxiliary electrode, a second orientation state of the auxiliary electrode, or a waveform characteristic of an applied electric current;
• training, based on at least one simulated electroforming process, a machine learning algorithm based on at least a subset of the set of training electroforming process parameters;
• validating the machine learning algorithm based on a set of measured electroforming process parameters corresponding to at least one actual electroforming process;
• generating a set of updated operating electroforming parameters from at least one of the training or the validating;
• and
• operating the electroforming apparatus based on the set of updated operating electroforming parameters, wherein operating the electroforming apparatus comprises:
• applying the applied electric current between the anode and the cathode in a presence of the electrolyte, and
• depositing a plurality of metal layers on a surface of the cathode to form the component.