Spark plug electrode and method of manufacturing the same

An additive manufacturing process for manufacturing a spark plug electrode, comprising the steps of:

• providing an electrode body that includes an electrode base and a heat dissipating core that is at least partially surrounded by the electrode base, whereby the electrode body is severed or cut through the heat dissipating core so that an axial end of the electrode base and a truncated axial end of the heat dissipating core are exposed;
• during an initial cycle, covering a firing end of the electrode body with an initial thin powder bed layer that includes a precious metal-based material, the initial thin powder bed layer contacts the axial end of the electrode base and the truncated axial end of the heat dissipating core;
• during the initial cycle, directing a laser or an electron beam at the firing end of the electrode body such that it melts or sinters at least some of the initial thin powder bed layer and portions of the electrode base and the heat dissipating core, and causing the melted or sintered materials to at least partially solidify into an initial laser deposition layer;
• during a subsequent cycle, covering the firing end of the electrode body with a thin powder bed layer that includes a precious metal-based material, the thin powder bed layer contacts a previously formed laser deposition layer;
• during the subsequent cycle, directing the laser or the electron beam at the firing end of the electrode body such that it melts or sinters at least some of the thin powder bed layer and portions of the previously formed laser deposition layer, and causing the melted or sintered materials to at least partially solidify into a newly formed laser deposition layer;
• and
• repeating the covering and directing steps of the subsequent cycle so that an electrode tip with a plurality of laser deposition layers and a sparking surface is formed on the electrode base, wherein the electrode tip is directly thermally coupled to the heat dissipating core.