Methods of Operating Electrochemical-Additive Manufacturing Systems Comprising Modular Cartridge Assemblies

A method for electrochemical additive manufacturing, the method comprising:

• assembling a modular cartridge assembly comprising a base, a cover, an ECAM printhead comprising an electrode array, a support unit, a control board external connector, and a busbar external connector;
• positioning the modular cartridge assembly on a modular-cartridge-assembly support comprising an assembly support thermal plate, an assembly support signal connector, and an assembly support power connector, wherein, after positioning the modular cartridge assembly on the modular-cartridge-assembly support:
• the assembly support signal connector is connected to the control board external connector,
• the assembly support power connector is connected to the busbar external connector, and
• the assembly support thermal plate directly interfaces and is sealed against the support unit;
• reducing pressure within a sealed assembly cavity collectively formed by the base, the cover, the ECAM printhead, and the support unit thereby forcing the ECAM printhead against the support unit and also forcing the support unit against the assembly support thermal plate;
• and
• performing the electrochemical additive manufacturing by:
• providing an electrolyte solution between and in contact with the electrode array of the ECAM printhead and a cathode,
• delivering a current to a subset of electrodes in the electrode array, and
• depositing a material from electrolyte onto a portion of the cathode aligned with the subset of electrodes in the electrode array.