Non-electrolytic deposition of electrode for pulsed electrochemical machining

A pulsed electrochemical machining (pECM) tool, comprising:

• a tool body defining a tool axis, the tool body comprising:
• a support substrate, wherein the support substrate comprises an electrically non-conductive material;
• and
• an electrode on a deposition surface of the support substrate, wherein the electrode comprises one or more layers of an electrically conductive material and defines a working surface configured to face a workpiece, and wherein the working surface of the electrode substantially mirrors the deposition surface of the support substrate.

A pulsed electrochemical machining (pECM) system, comprising:

• a pECM tool comprising a tool body defining a tool axis, the tool body comprising:
• a support substrate, wherein the support substrate comprises an electrically non-conductive material;
• and
• an electrode on a deposition surface of the support substrate, wherein the electrode comprises one or more layers of an electrically conductive material and defines a working surface configured to face a workpiece, and wherein the working surface of the electrode substantially mirrors the deposition surface of the support substrate;
• a mechanical system configured to position the working surface of the electrode relative to the workpiece;
• an electrolyte system configured to supply electrolyte to the mechanical system for delivery to an interelectrode gap between the working surface of the electrode and a target surface of the workpiece;
• and
• a power supply configured to generate an electric potential between the electrode of the pECM tool and the workpiece.