Electroforming apparatus and method for forming a rib

Abstract

Aspects of the disclosure generally relate to an electroforming apparatus and method, including a support frame with at least one anode housing having a predetermined housing geometry. At least one anode can be carried by the at least one anode housing, and the at least one anode can also include a predetermined geometry.

1 . An electroforming apparatus, comprising:
 a support frame with a frame base and at least one anode housing projecting from the frame base and having a predetermined housing geometry; and   at least one anode carried by a tip of the at least one anode housing and having a predetermined anode geometry, the at least one anode being configured to electrically couple to a power source.   
     
     
         2 . The electroforming apparatus of  claim 1  wherein at least a portion of the tip is complementary to at least a portion of the predetermined anode geometry. 
     
     
         3 . The electroforming apparatus of  claim 1  wherein at least one of the predetermined housing geometry or the predetermined anode geometry is at least one of flat, curved, or V-shaped. 
     
     
         4 . The electroforming apparatus of  claim 1  wherein the at least one anode comprises a non-sacrificial anodic material, and wherein the support frame comprises a non-conductive material. 
     
     
         5 . The electroforming apparatus of  claim 4  wherein the non-conductive material comprises plastic, and wherein the non-sacrificial anodic material comprises titanium. 
     
     
         6 . The electroforming apparatus of  claim 1  wherein the support frame surrounds at least a portion of the at least one anode. 
     
     
         7 . The electroforming apparatus of  claim 6  wherein the support frame extends along at least a portion of a sidewall of the anode forming a length of the anode. 
     
     
         8 . The electroforming apparatus of  claim 7  wherein the support frame extends distally beyond the sidewall of the anode. 
     
     
         9 . The electroforming apparatus of  claim 7  wherein the support frame is configured to reduce electric field edge effects at the sidewall of the anode. 
     
     
         10 . The electroforming apparatus of  claim 1  wherein the support frame houses two anodes spaced from each other. 
     
     
         11 . A system for electroforming a component, comprising:
 a fluid reservoir containing an electrolytic fluid;   a substrate located within the fluid reservoir and defining a cathode; and   an electroforming apparatus, comprising:
 a support frame with a frame base and at least one anode housing projecting from the frame base and having a predetermined housing geometry; and 
 at least one anode carried by a tip of the at least one anode housing and having a predetermined anode geometry, the at least one anode being configured to electrically couple to a power source. 
   
     
     
         12 . The system of  claim 11 , further comprising at least one anode housing coupled to a moveable support frame and having a predetermined anode geometry, wherein the at least one anode comprises a non-sacrificial anode carried by a tip of the at least one anode housing. 
     
     
         13 . The system of  claim 12  wherein the predetermined anode geometry is at least one of flat, curved, or V-shaped. 
     
     
         14 . The system of  claim 11  wherein the substrate is a curved portion of a pressure vessel and the system is configured to electroform a protrusion on the curved portion. 
     
     
         15 . The system of  claim 11 , further comprising a non-conductive support frame surrounding at least a portion of the at least one anode. 
     
     
         16 . The system of  claim 15  wherein the non-conductive support frame is further configured to provide electrolyte jets toward the substrate. 
     
     
         17 . The system of  claim 15  wherein the non-conductive support frame is translatable at least vertically within the fluid reservoir. 
     
     
         18 . A method of forming a component, the method comprising:
 providing a substrate in a fluid reservoir containing an electrolytic fluid and at least one anode located within a corresponding at least one anode housing having a predetermined housing geometry;   electrically coupling the substrate to a power source such that the substrate is configured to form a cathode; and   electroforming a protrusion on the substrate;   wherein the at least one anode has a predetermined anode geometry configured in relation to the cathode to increase a local current density within the electrolytic fluid during electroforming such that a local deposition rate on the cathode is increased at the location of the protrusion.   
     
     
         19 . The method of  claim 18  wherein a spacing distance between the at least one anode and the cathode is configured to increase the local current density during electroforming such that at local deposition rate on the cathode is increased. 
     
     
         20 . The method of  claim 18  wherein a non-conductive support frame surrounds at least a portion of the at least one anode, and wherein the non-conductive support frame extends distally beyond a length of the at least one anode. 
     
     
         21 . The method of  claim 18  wherein the protrusion at least partially defines an elongated stiffening rib. 
     
     
         22 . The method of  claim 21 , further comprising forming multiple stiffening ribs. 
     
     
         23 . The method of  claim 22  further comprising simultaneously forming the multiple stiffening ribs. 
     
     
         24 . The method of  claim 22  wherein the multiple stiffening ribs define an isogrid pattern. 
     
     
         25 . The method of  claim 21 , further comprising electroforming a second portion of the stiffening rib via the at least one anode. 
     
     
         26 . The method of  claim 21 , further comprising moving the anode away from the substrate to maintain a relatively constant gap while forming a second portion of a stiffening rib. 
     
     
         27 . The method of  claim 18 , further comprising providing a low-velocity impinging jet of electrolytes during the electroforming.