Electrochemical micromanufacturing system and method

An electrochemical printer system comprising:

• a source of pressurized electrolyte;
• a conductive substrate disposed in a container;
• an electrochemical printing head having a plurality of electrodes, each electrode having a channel therethrough, a plurality of electrical leads wherein each electrical lead is electrically connected to at least one electrode, the electrical leads extending accessibly from the printer head for connection to an electric power source, a high electrical resistance means for controlling the distribution of the electrolyte to the electrode channels, and a resolution-defining layer disposed below the plurality of electrodes, the resolution-defining layer having a plurality of apertures that provides an outflow path for the electrolyte from the electrode channels;
• a power source electrically connected to the conductive substrate and selectively connectable to each of the plurality of electrodes such that a circuit is formed between the selected electrodes, the electrolyte, the conductive substrate, and the power source;
• and
• an actuator for moving the conductive substrate with respect to the electrochemical printing head.

A method for producing a functionally-graded material deposit comprising:

• providing a conductive substrate in a container containing a liquid electrolyte;
• providing an electrochemical printer head having a plurality of electrodes with a channel therethrough for each electrode, the electrochemical printer head having a surface positioned in close proximity to the conductive substrate, wherein the electrochemical printer includes a plurality of flow paths therethrough, at least some of the flow paths including at least one of the electrode channels;
• providing electrolyte under pressure to the electrochemical printer head such that electrolyte flows through at least some of the plurality of flow paths and is expelled toward the conductive substrate through a resolution-defining layer disposed below the plurality of electrodes;
• selectively applying an electric potential between the conductive substrate and at least one of the plurality of electrodes such that a circuit is formed between the electrode, the electrolyte, and the conductive substrate;
• and
• varying the flow rate of the electrolyte through the electrochemical printer head and a parameter of the applied electric potential to produce a functionally graded material deposit.