Alexandria Engineering Journal (2021) xxx, xxx–xxx

H O S T E D BY
Alexandria University

Alexandria Engineering Journal

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A critical insight into the use of FDM for

production of EDM electrode
Azhar Equbal a, Md. Israr Equbal b, Irfan Anjum Badruddin c,*, Ali Algahtani c

a
Faculty of Engineering and Technology, Department of Mechanical Engineering, Jamia Millia Islamia, New Delhi 110025, India
b
Mechanical Engineering Section, University Polytechnic, Aligarh Muslim University, UP 202001, India
c
Mechanical Engineering Department, College of Engineering, King Khalid University, Abha 61413, Asir, Saudi Arabia

Received 19 June 2021; revised 3 September 2021; accepted 12 September 2021

KEYWORDS Abstract The goal of this work is to shed light on the importance and application of FDM (Fused
Fused deposition modelling; Deposition Modelling) in the production of electrodes for die-sinking EDM (Electrical Discharge
Electrical discharge machin- Machining). A literature-based survey is conducted, and it is discovered that the applicability of
ing; FDM for manufacturing EDM electrodes has received little attention. The quantity of articles
Electrode; on this issue is exceedingly low in conventional data bases such as Web of Science and Scopus.
Spark; The purpose of this study is to offer relevant investigations and demonstrate the convenience, merit,
Workpiece; and limitations of the method used. The review offered in this work is intended to assist researchers,
Coating practitioners, and scientists in making informed decisions on which method to use to meet their
needs. The authors have been inspired by the study trend to encourage scholars and researchers
to investigate the applicability of the FDM technique in the fabrication of EDM electrodes further.
The review is based on the most recent database from Web of Science, Scopus, and Google Scholar,
using the keywords FDM/Fused Deposition Modeling and AM/Additive Manufacturing.
Ó 2021 THE AUTHORS. Published by Elsevier BV on behalf of Faculty of Engineering, Alexandria
University. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/
licenses/by-nc-nd/4.0/).

1. Introduction

Die sinking EDM is a non-traditional machining technique in

which material is removed as small particles (debris) via melt-
Abbreviations: AM, Additive Manufacturing; ABS, acyrilo-nitrile ing and vaporization [1]. The working mechanism of Die-
butadiene styrene; CE, Copper electroplated; Cu, Copper; DMLS, sinking EDM is depicted schematically in Fig. 1. A servo con-
Direct metal laser sintering; ELP, electroless plated; FDM, Fused troller keeps the space between the electrode and the workpiece
deposition machining; MRR, Material removal rate; MMC, Metal constant, allowing for repetitive discharges [2]. The machining
matrix composites; Ra, Surface roughness; SC, Solid copper; SLS,
is carried out entirely in a dielectric fluid, which is usually a
Selective laser sintering; SLA, Stereolithography; TWR, Tool wear rate
* Corresponding author. hydrocarbon and silicon-based oil [3]. EDM is employed in a
E-mail address: magami.irfan@gmail.com (I.A. Badruddin). variety of industries, including aerospace, autos, and electron-
Peer review under responsibility of Faculty of Engineering, Alexandria ics [4]. Details about EDM can be found in other publications
University. [2–4]. During machining with Die-sinking EDM, an electrode
https://doi.org/10.1016/j.aej.2021.09.033
1110-0168 Ó 2021 THE AUTHORS. Published by Elsevier BV on behalf of Faculty of Engineering, Alexandria University.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
Please cite this article in press as: A. Equbal et al., A critical insight into the use of FDM for production of EDM electrode, Alexandria Eng. J. (2021), https://doi.org/
10.1016/j.aej.2021.09.033
2 A. Equbal et al.
Battery Capacitor Resistor
supply
Gap
Workpiece
Fig. 1 Schematic of Die-sinking EDM.
duplicate is replicated in the workpiece [4]. Complex electrode
profiles are required for machining complex cavities in EDM,
and manufacturing such complex profiles is difficult and time-
consuming [5].
According to previous studies, additive manufacturing
(AM) procedures can effectively satisfy the complexity, timeli-
ness, and economy of EDM [4]. Stereolithography (SLA) and
selective laser sintering (SLS) were the main topics of EDM
research [6]. They, however, fell short of the criterion. Selective
laser sintering creates conductive electrodes directly from
metal powders, but technique is plagued by porosity, which
has an impact on electrode characteristics and mechanical
strength [7]. On the other hand, stereolithography-produced
electrodes must be metalized before use, and their metalliza-
tion is not well understood [8]. The paper’s third section con-
tains a detailed description of studies on EDM electrode
fabrication using different AM techniques such as SLA and
SLS, as well as the issues that have been encountered.
Another additive manufacturing (AM) method is fused
deposition modeling (FDM), which is known for constructing
any complex object in a short amount of time with minimal
human participation. Plastic-based working materials, such
as epoxies and ABS, are commonly used in FDM (acyrilo-
nitrile butadiene styrene). ABS may be easily metalized,
according to the literature, and thus they provide a lot of
potential in the creation of an electrode for EDM [9–12]. These
benefits have prompted academics and practitioners to adopt
FDM to make EDM electrodes. Critical and collective litera-
ture demonstrating the relative ease, advantages, and limita-
tions of FDM-related research can aid the research
community in selecting the most appropriate method for their
needs. Authors are encouraged to emphasize that, despite the
fact that the SLA and SLS pathways produce inferior results,
efforts are ongoing to improve these procedures and make
them more suited for the fabrication of EDM electrodes [13–
22]. Although there has been little research on FDM for elec-
trode manufacture, it has shown tremendous promise in the
fabrication of electrodes. The fact that there are so few studies
on the subject suggests that there is a pressing need for timely
assessment in this field. The authors are thus motivated by
study statistics to encourage academics to expand their
FDM-related EDM inquiry. The following is the structure of
the paper: Section 2 of the study briefly outlines AM technolo-
gies with special relevance to the FDM process; Section 3 pre-
sents EDM-related SLA and SLS research. In Section 4, the
current state of the literature (FDM in EDM electrode fabrica-
Servo Controller
Electrode
EDM Tank
Debris
Crater Spark
tion) is summarized, followed by a comparison of electrode
quality produced by FDM and other AM approaches (Sec-
tion 5). Section 6 contains a summary of the research. The con-
clusion and future scope of the paper are presented in the final
section.
2. AM technologies
Additive manufacturing (AM), often known as digital manu-
facturing, is a new method that fabricates part shape by
depositing materials in successive layers [23]. The tessellation
of the CAD (computer-aided design) model, in conjunction
with the machine settings, determines the layer thickness.
AM allows for the manufacture of any geometry in the short-
est amount of time without the use of a separate process plan
or special tooling [24]. As shown in Fig. 2, the process chain
comprises of five important phases. The process chain for all
AM processes is the same. Pre-processing includes the first
three phases, which are followed by part fabrication and
post-processing. Prototyping, construction, industrial, and
medical industries all use AM [3]. According to ASTM world-
wide Designation: F2792-12a [25], FDM is a major version of
AM that comes under the material extrusion process. Fig. 3 is
a schematic diagram of FDM. Wire-based part material is
passed via rollers and directed to the liquefier, where it is
heated past the glass transition temperature to form a paste.
The pasted material extrudes from the nozzle and binds to
the material that was previously deposited [26]. The support
material must support the created structure if the section to
fabricate is thin or overhung.
In the FDM machine, two nozzles are used: The build
material is deposited by the first nozzle, while the support
material is deposited by the second. The brittle support mate-
rial is deposited first, followed by layers of component mate-
rial. Fusion bonding occurs when heat is exchanged between
the newly deposited material and the previously placed layer
[27]. The entire procedure is carried out in a chamber that is
kept at a constant temperature. The nozzles return to their
original places after the FDM part is finished, and the part
is removed from the chamber. Depending on the type of the
support material, it is either physically or through ultrasonic
vibrations removed from the part. The most often used
FDM part materials are ABS (acrylonitrile–butadienestyrene),
Polycarbonate (PC), ABSi (high impact grade of ABS), PC-
ISO, and PC-ABS [28]. According to previous research, the
optimal configuration of FDM settings produces a product
A critical insight into the use of FDM
CAD design Translation to
.STL file
Post processing
Fig. 2 Main steps in AM processes.
Canister for
part material
Rollers
Part
Table
Fig. 3 Schematic of FDM machine.
with exceptional dimensional precision, increased mechanical
strength, and outstanding surface quality [4,8,28]. Further-
more, ABS has good metallization capabilities, making it a
suitable material for EDM electrode manufacturing utilizing
FDM, as has been proven in the literature.
3. EDM electrode production using other AM techniques
Using AM, EDM electrodes can be made from both conduc-
tive and non-conductive materials. This section contains in-
depth explanations of related studies.
3.1. Electrodes of conductive material
Currently, EDM electrode fabrication with conductive materi-
als research focuses on expanding the list of materials available
and improving their performance. SLS (selective laser sinter-
ing) is the most commonly studied method in this area. Metal
and alloy powders, as well as binders, are utilized in the SLS
process to create parts. Direct metal laser sintering (DMLS)
and indirect metal laser sintering (IMLS) are the two main
methods utilized in SLS. IMLS, on the other hand, uses a plas-
tic binder in addition to metal powders to create tools and pro-
totypes. Durr et al. [16] were the first to study the use of
DMLS for EDM electrode fabrication. During the process,
nickel, bronze, and a little amount of copper phosphite pow-
ders were employed. The machining rate was satisfactory,
however there was a high rate of tool wear and unsatisfactory
surface roughness (Ra). A more accurate electrode dimension
was suggested for little tool wear and an excellent surface pol-
3
Determination of building
parameters and support
structure
Part fabrication
Canister for
support material
Liquefier
Head
Extrusion Nozzle
Support material
ish. Due to the porosity in DMLS electrodes, Meena et al. [29]
investigated and concluded that electrode wear at the front
edge was larger than that at the side. DMLS was also used
to make EDM electrodes by Tay and Hyder [17]. Solid copper
(SC), copper electroplated (CE), electrolessly copper plated,
and plain DMLS electrodes are the four types of electrodes
they make. Machining was done with these four electrodes
under various situations, and it was discovered that while
DMLS electrodes are better for removing the least amount
of material, ECP electrodes may remove intermediate amounts
of material with minimal dimensional errors. The thickness of
copper-plated DMLS electrode shells was also studied [18].
Copper electroplating of complex DMLS pieces (with fine fea-
tures and slopes) was done, and the thickness of the copper
layer was measured at several points. It was observed that
the copper deposition is better in the exterior and plainly visi-
ble sections than in the portions with inner cavities and fine
features. Copper electroplated DMLS electrodes were found
to be unsuitable for industrial usage as a result of the inconsis-
tent thickness of the copper coating across the whole part,
according to their research.
Due to the troublesome powder expansion found during
the procedure, IMLS research has mostly focused on generat-
ing innovative materials with enhanced characteristics. Metal
matrix composites (MMC) were used to test the feasibility of
generating EDM electrodes [14,15,30–33]. Cold pressing of
ZrB2 powder coupled with a polymer binder was used to make
simple electrodes, whereas SLS was used to make complex
electrodes. Copper infiltration was used to back up the sinter-
ing of ZrB2 particles in a temperature-controlled furnace. The
effects of current (I), pulse on time (Ton), and pulse off time
4 A. Equbal et al.
(Toff) on tool steel machining were investigated. The material
removal rate (MRR) rises with I until it reaches a critical point
in Ton, at which point it starts to fall. MRR was also
investigated by altering Toff while keeping Ton constant. With
an increase in Ton, the tool wear rate (TWR) decreased. Elec-
trodes with variable copper (Cu) compositions were made
using ZrB2 and TiSi [6]. Cu-TiSi electrodes had poor perfor-
mance, however Cu-ZrB2 electrodes had a low MRR and a
high TWR when compared to typical electrodes. Poor bonding
between Cu and ZrB2 particles could be the cause. Li et al. [34]
investigated the effect of sintering on copper-based electrodes,
finding that electrodes containing 15% TiC had good electrode
characteristics and EDM performance. Zhao et al. [35] devel-
oped an electrode employing steel powder, polyester, and
phosphate. Sintering at low temperature was used to degrade
the polyester in the third step of the post-treatment process.
After the phosphate-steel reaction, sintering at high tempera-
tures created stiff inorganic compounds, and Cu infiltration
was done in the final phase to increase electrode quality. These
electrodes can only be used for finish machining, according to
real-time machining at various settings. Fred et al. [36] exam-
ined the SLS approach for manufacturing EDM electrodes.
Pure Cu powder, steel alloy DS20 powder, bronze-nickel
(Br-Ni) alloy powder, and 50 vol% pure copper 50 vol%
standard bronze-nickel alloy powder were used. Machining
conditions were used to test the electrodes that were made.
Steel alloy and bronze-nickel alloy demonstrated good densifi-
cation and the lowest porosity in a comparative investigation.
When compared to SC electrodes, however, MRR and TWR
were found to be better with SC electrodes. Tiago et al. [21]
studied the effect of SLS factors and material content on den-
sification behavior and porosity in rapid electrode manufactur-
ing utilizing Cu powder, Cu-Ni, and ZrB2 in SLS. They
observed that CuNi-ZrB2 electrodes performed better than
Cu-powder electrodes, but that their performance was still
inferior to SC electrodes.
3.2. Electrodes of Non-conductive material
Positive metal plated AM parts and negative metal plated AM
parts are two types of electrodes made with the AM process
and non-conductive part materials. The surface of the AM
part is cleaned before being subjected to primary metallization
in order to induce conductivity in non-conductive parts. Sec-
ondary metallization is applied over the original metallized
layer to increase the coating thickness (in order to meet
EDM requirements). All three procedures are employed for
positive metal plated components, however for negative metal
plated parts, two further sub processes are added, namely
backfilling with suitable material and mandrel removal, in
addition to the three sub processes already mentioned.
SLA (stereolithography) pieces were plated with copper
and machining was done to make the electrodes for EDM
[37]. In finishing and semi-finish EDM, acceptable results were
obtained, however electrodes were found to be inappropriate
for the roughing phase. They proposed that for common
EDM application, coating thickness more than 180 mm (m)
be employed. The distribution of heat in SLA electrodes has
also been investigated [20,38]. They observed that shear stress
was formed in the interfaces due to different linear expansion
between the inner plastic core and the outside metallized layer,
resulting in electrode failure. Between room temperature and
the temperature range in EDM, there was a significant decline
in copper’s electrical conductivity. Gillot et al. [39] evaluated
the accuracy of CE (copper electroplated) electrodes. They
claim that the dimensional accuracy of electrodes is deter-
mined by the precision of the AM model and the metallized
thickness produced. They further claimed that CE electrodes
were unsuitable for industrial application due to their lack of
dimensional accuracy. Dickens et al. [13] looked into spray
metal deposition on SLA parts. Electroplating and electro-
forming were shown to be superior than the spraying approach
used for metallization. Soar et al. [40,41] looked into the spray
approach as well. They also stated that the finished electrode’s
characteristics are subpar. SLA pieces were electroformed by
Yang et al. [40]. The backfilling was then done with a low melt-
ing point alloy. However, the metallization uniformity was not
maintained, and EDM was used. SLA component burning and
backfilling material solidification were observed, resulting in
electrode deformation and higher dimensional errors. Arthur
et al. [42] also created electrodes by electroforming and back-
filling a negative AM model.
Silver paint was applied to a dome-shaped electrode with
no holes or features, which was then subjected to acidic copper
deposition. Adhesives were used to secure a copper shaft into
the rear. The performance of the fabricated electrode was
tested under various conditions and found to be satisfactory.
They claim that it is difficult to separate the shell from the neg-
ative SLA body. They also suggested that stair stepping of
SLA parts be avoided, especially for curved electrodes and
electrodes with precise features. Electroforming with copper
over AM mandrels was also investigated, and thin walled elec-
troformed electrodes backfilled with correct material were
found to be suitable for EDM electrodes operating at low cur-
rent [43]. At room temperature, the SLA part was produced
and vulcanized with silicon. The construction of flexible silicon
cavities is then done using vacuum castings [44]. Copper elec-
troforming was used to create copper shells in cavities. To pro-
vide the electrode enough strength, the shells were warmed and
the backing was done with zinc. Due to the lack of backfilling,
distortion was noticed, leading to the conclusion that the elec-
troformed electrode exhibits uneven shell thickness.
Electroformed electrodes are made with SLA and Thermo
Jet mandrels [45,46]. Uneven shell thickness was noted during
testing with SLA mandrels at cavities and features that were
crucial in early electrode wear. When THJ mandrels were uti-
lized for machining, the same result was obtained. For EDM
electrode manufacturing, Hsu et al. [47] use gypsum powders
(ZP100) in a Zcorp 402 3DP rapid prototyping machine.
Nickel electroless plating (ELP) was used first, followed by
copper electroforming. Surface roughening (etching) is an
essential phase in ELP, according to their research. They dis-
covered that machining with the created electrode is possible,
and they proposed that an electrode for EDM might be made
utilizing an AM technique combined with ELP and electro-
forming. They also found that, as compared to CNC machin-
ing, electroless plating paired with electroforming can shorten
the time it takes to make an electrode. Sreenathbabu et al. [48]
looked at the hybrid adaptive AM method and found that
while accurate tools could be made, they had inferior compo-
sition and tool life.
Despite its numerous advantages, the research trend shown
above suggests that AM methods have their own limitations in
A critical insight into the use of FDM
terms of part quality. For EDM, the fabricated object must
have great dimensional accuracy, a smooth surface finish,
and sufficient strength to endure the intense machining condi-
tions produced during the machining process. As a result,
before suggesting the technique for industrial use, it is vital
to comprehend its flaws.
4. EDM electrode production using FDM
EDM is a common machining technique for hard and brittle
conductive materials such as tungsten, titanium, and superal-
loys [49,50]. Complex machining frequently necessitates the
use of a complex electrode, which is difficult to achieve using
traditional machining processes such as turning, grinding,
and milling [2,4,5]. Traditional technologies are unable to
match the need for complex structures in a shorter time frame.
Although AM-related techniques such as selective laser sinter-
ing and stereolithography can manufacture such electrodes,
the electrodes produced by these techniques do not match
the EDM requirements (as discussed in Section 3). Further-
more, investigations on AM have demonstrated that using
FDM to make electrodes can overcome the limits of conven-
tional AM methods and generate electrodes that meet EDM
criteria successfully [9–12,51–53,56,57]. There have been a
few studies on the use of FDM in the manufacturing of
EDM electrodes, but there has yet to be a conclusive study that
provides insight into the usage of FDM in the preparation of
EDM electrodes. This article includes a review to assist with
that
Reddy et al. [51] studied the electrical conductivity of ABS
and PLA-based EDM electrodes manufactured using FDM.
The produced electrodes from ABS and PLA were cleaned
and metalized with copper using the electroless deposition
method. The traditional electroless method was followed in
its entirety. Deposition was carried out using two types of elec-
troless baths: concentrated (100gm CuSO4; 300gm HF) and
diluted (20gm CuSO4; 60gm HF; 200 ml deionized water). It
was discovered that conductivity increased with deposition
time, with the highest conductivity being achieved after 48 h.
The best PLA samples had higher conductivity than the ABS
samples, according to the researchers. Finally, they discovered
that material with 100 percent infill had superior conductivity
than material with a lower infill percentage. They were able to
manufacture FDM electrodes for EDM, but no real-time
machining was done, and the findings were not confirmed.
Savan and Karajagikar [52] conducted the first real-time
EDM using an FDM-produced electrode. They compared
the machining performance of En-19 alloy steel utilizing pure
copper versus metalized FDM electrode. Machining copper
parts on a CNC machine generated a copper electrode. For
FDM-based electrode preparation, an FDM part with the req-
uisite shape and dimension was created and then electrolessly
plated with copper. A covering of 700 mm was applied to
FDM manufacture electrodes to match EDM’s thickness
requirement. Both electrodes were used for 35 min of EDM,
and their performance was tested in terms of MRR, TWR,
and surface roughness (Ra). They discovered that the machin-
ing performance of the metalized FDM electrode was compa-
rable to that of the solid copper electrode under similar
machining conditions. Metalized FDM electrodes were also
found to be better appropriate for completed machining oper-
5
ations. Finally, they proposed that in EDM, a metalized FDM
electrode may be used instead of a solid copper electrode. Equ-
bal et al. [4] conducted the following experimental inquiry in
this direction. In their research, they used solid copper and
FDM manufactured electrodes to EDM mild steel. Copper
machining was used to create a solid copper electrode with
the requisite shape and diameter. Electroless copper deposition
was used to prepare the FDM electrode, which was then elec-
troplated. The maximum electrode wear was determined to
establish the thickness required of the copper-plated FDM
electrode after machining with a copper electrode at various
parameter settings. It was also suggested that a governing
equation be used to adjust the thickness of the coating depend-
ing on the coating situation. EDM was performed with these
electrodes using response surface methods, with current,
spark-on time, and spark-off time as machining factors. A
comparison of the machining performance of both electrodes
in terms of MRR, TWR, Ra, and dimensional accuracy was
also conducted. According to the findings of the investigation,
FDM produced electrodes outperformed solid copper elec-
trodes. However, it was discovered that both electrodes created
large holes in terms of dimensional precision. Furthermore, the
entire EDM was carried out with a single solid copper elec-
trode, whereas the machining of a single cavity was carried
out using separate FDM electrodes. Multi-objective optimiza-
tion was used to find the best machining conditions for FDM
manufactured EDM electrodes. The FDM procedure for the
manufacturing of EDM electrodes was studied by Saxena
and Metkar [53]. ABS quadrilateral shaped pieces were pro-
duced and electroless plated with 2 mm copper film. Solid cop-
per rod was also used to make a CNC machined copper
electrode with a similar quadrilateral shape. Taguchi design
of experiments was used to conduct experiments on an SS 50
Spark Generator EDM equipment. Machining variables
included current, pulse on time, and duty factors, with machin-
ing results assessed in terms of MRR and EWR (Electrode
wear rate). The researchers discovered that both FDM pro-
duced electrodes and conventional solid copper electrodes
had equivalent machining performance. They also proposed
that worn-out electrodes with complex profiles may be quickly
recreated using FDM electrodes, but that this would only be
practical in limited quantities. EDM electrodes were success-
fully manufactured utilizing the FDM technique, but the
approach was not properly stated, and the depth of the
machined cavity was not provided to determine the electrodes’
appropriateness under various machining conditions. Further-
more, the machined dimensions revealed that the machining
was completed in a fairly short period of time. The feasibility
of FDM electrodes for EDM of Ti-6Al-4V alloy was explored
by Mohsen and Mohammad [54]. EDM was done in two ways:
one with aluminium powder mixed in the dielectric, and the
other without any powder added. Surfactant was added to
the dielectric (kerosene) while machining in powder mixed con-
dition to separate and distribute the particles. On the FDM
electrode, a 3 mm thick copper coating was applied, and a con-
ventional electrode was created on a CNC machine using the
copper bar. These electrodes’ machining performances were
compared in terms of MRR, TWR, and Ra. FDM electrodes
used in powder mixed EDM showed good potential for cutting
complex forms, according to the researchers. When compared
to machining without adding the powder to the dielectric,
6 A. Equbal et al.
powder mixed EDM employing both electrodes resulted in
improvements in MRR, TWR, and Ra. They also discovered
that when aluminium powder was combined with dielectric
during EDM machining of Ti-6Al-4V alloy, the average sur-
face quality was greatly enhanced. They found that the coating
thickness, coating quality, and machining setting all affect how
well FDM-based electrodes work. However, the coating pro-
cess used for metallization of plastic-based FDM electrodes
was not revealed in their study, and machining dimensions
were also missing. Electroless plating is used by Pawar et al.
[55] to metallize copper over FDM parts made with ABS as
the part material. To meet the EDM requirements, a metalliza-
tion thickness of 1.5 mm was given, and EDM was accom-
plished using the Taguchi L9 orthogonal array. MRR,
TWR, and Ra as output responses were used to optimize per-
formance. When comparing voltage and pulse on time, they
discovered that current is the most prominent factor. Finally,
the primary effect plot was utilized to determine the best set
of parameter settings for attaining the best results. Padhi
et al. [56] evaluated the performance of a tool electrode created
on FDM samples using copper electroplating. Two stepped
cylindrical electrodes were produced, and D2 steel plate
machining was completed. The electrode was plated to a thick-
ness of 1000 m and real-time machining was performed. Only
8 m of wear was recorded when machining a depth of 3500 m
on D2 steel, and relative wear was computed as 0.29 percent.
When compared to results achieved with a solid copper tool,
the MRR and TWR obtained with a quick tooling electrode
(copper electroplated electrode) are comparable to those
obtained with a solid copper tool. They deduced that after a
metallized layer has been completed or worn out, the same
electrode can be metalized selectively and in line with calcula-
tions for reuse. They also claimed that the technique will cut
metallization time and material consumption, as well as the
tool’s cycle time and cost. Dande et al. [57] investigated the
machining performance of a 3D-printed ABS part (through
FDM) electroplated with copper for use as an EDM electrode.
The CE electrode’s performance is compared to that of a SC
electrode with the same outside dimension. The MRR,
TWR, and Ra are used to evaluate the performance. For each
performance measure examined, copper electroplated elec-
trode performed identically to solid electrode. They conclude
that the weight of copper electroplated electrodes is less than
1/3rd that of solid electrodes, making plated electrodes easier
to use. They also suggest that plating complex electrode pro-
files may be difficult, and that the accuracy of plated electrodes
may vary, but that it can still be utilized as a solid electrode
replacement.
5. Comparative study on performance of EDM electrode
produced using FDM and other AM processes
The discussion in Section 3 concludes that AM methods may
undoubtedly be utilized to manufacture EDM electrodes; how-
ever, previous relevant research has focused on SLS [20,37–39]
for conductive materials and SLA for non-conductive materi-
als [40,41,43,44,48]. The results produced with SLS based
EDM (SLS-EDM) electrodes and SLA based EDM electrodes
(SLA-EDM) electrodes are not promising, and they vary
depending on the investigation. When a laser was conducted
through SLS-EDM electrodes made of metal powders or a
mixture of metal powders, significant porosity was found due
to incorrect powder particle fusion when the laser was sent
through them [29]. SLS-EDM electrodes have been found to
be suitable for little material removal, however electrode wear
is higher, and the surface quality is poor [17]. Some studies
claimed that SLS-EDM electrodes are only suited for finish
cuts, while others suggested that they are unsuitable for indus-
trial use [18]. SLA-EDM electrodes, on the other hand, neces-
sitate metallization in order to achieve the appropriate metal
thickness on the plastic substrate. When metalized thickness
more than 180 m is employed in EDM, these electrodes are
proposed for semi-finishing and finishing electrodes [37]. The
quality of the final SLA-EDM electrode was also observed
to be poor because: I the linear expansion between the inner
plastic core and the outer metalized layer was varied, creating
shear stress at interfaces [20,38]. (ii). Non-uniform shell thick-
ness deposited in different sections of the electrode, particu-
larly when the electrodes have curved geometries, recesses,
and features [44]. (iii). Incomplete backfilling causes electrode
deformation [44] and (iv). Electroplated electrodes offer unsat-
isfactory results due to dimensional inaccuracies [39].
FDM-EDM electrodes employ ABS as the base material,
and ABS metallization is well established, therefore FDM-
EDM electrodes may overcome the restrictions of other AM
methods (SLS and SLA) and make electrodes that satisfy
EDM criteria. Some researchers have successfully manufac-
tured the electrode but have not performed machining with
it or have done so for a shorter period of time [51,53].
Researchers that have made FDM-EDM electrodes and
machined them conclude that their performance is comparable
to or better than solid copper electrodes [4,53]. They concluded
that they can replace traditional electrodes since they are low
in weight and cost less to create in big quantities. They also
said that the effective usage of FDM-EDM electrodes is
dependent on the coating thickness and quality, as well as
the machining setup [54]. A feasible procedure for converting
non-conductive FDM parts into machining EDM electrodes
was proposed: electroless copper metallization followed by
copper electroplating. They’ve also devised a formula for elec-
troplating electrolessly copper plated electrodes [4]. The FDM-
EDM electrode outperformed the SLS-EDM and SLA-EDM
electrodes in terms of performance. However, because there
are few related studies, the performance of the FDM-EDM
electrode still needs to be investigated further before it can
be recommended as a method.
6. Summary
A review of the literature on the use of FDM produced elec-
trodes in the EDM process is offered. Only a few studies on
this topic have been discovered in the literature. However,
the available data shows that employing FDM produced elec-
trodes in EDM has a huge potential. In this study, we have
attempted to highlight previous research in this fascinating
area in order to properly illustrate the ease, benefits, and lim-
itations of using FDM produced electrodes in EDM. A sum-
mary version of the critical researches available in the
literature has been offered in tabular form to provide a better
understanding to the readers (Table 1). When assessed in terms
of MRR, TWR, and SR, the machining performances of FDM
electrodes were either superior or equivalent to traditional
A critical insight into the use of FDM 7

Table 1 Prominently referred papers for FDM in EDM electrode production.

Ref. No. and Summary
Machining performance of pure
copper and copper-metallized
FDM electrode for machining of
En-19 alloy steel were compared
[52].
Machining performance of
metallized FDM electrodes and
SC electrodes were compared in
terms of MRR, TWR, Ra and
dimensional accuracy [4].
Machining performance of FDM
electrodes and solid copper
electrodes were compared [53].
Feasibility of FDM electrodes for
EDM of Ti-6Al-4V alloy was
investigated. EDM was
performed in two conditions: one
with aluminium powder mixed
EDM and other is without any
powder added to dielectric.
Machining performance was also
compared with solid copper
electrodes [54].
Conclusions
FDM fabricated EDM electrodes
were more suitable for finished
machining operations and can
replace worn out complex metal
electrodes
Metallized FDM fabricated
electrodes were found to be more
suitable than solid copper
electrodes in all machining
conditions i.e. rough, semi-finish
and finishing operations.
Optimum machining condition
for better machining efficiency
was also proposed.
Electrode produced by FDM
showed similar machining
performance as that of
conventional copper electrode in
all respect. Worn out electrodes
having complex profiles were
required to be urgently replicated
with FDM electrodes.
Powder mixed EDM using both
FDM electrode and CNC
electrode indicated improvement
in MRR TWR and Ra.
Ease and merits Limitations or shortcomings
Metallized thickness of 700 mm Superficial machining was done
was easily provided on FDM only for 35 min and machining at
fabricated parts using simple rough conditions was missing.
electroless process. The results of
metallized FDM electrodes were
comparable to metal copper
electrodes.
Simple metallization methods Machining of different holes was
such as electroless and done using different metallized
electroplating methods were used. electrodes. Full machining
A governing equation to control capability of a single electrode
thickness of coating in was not investigated.
electroplating was also proposed.
Wearing of metallized FDM
fabricated electrode was lesser
than that of solid copper
electrode.
Electroless method was simple No standard literature was
and economic. Worn out followed and machining
electrodes having complex dimensions were missing.
profiles were required to be Moreover, the machined
urgently replicated with FDM dimensions showed that
electrodes. machining was performed for
short duration. Complete
investigations were missing.
Electrodes produced by FDM Coating method was not
showed good potential for disclosed. Machining dimensions
powder mixed EDM for were also missing.
machining of complex shapes.
Average surface quality was
significantly improved when
aluminium powder was mixed
with dielectric during machining

Ref. No. and Summary
Optimum performance of
electrode manufactured by
Electroless coating over ABS
part was performed [55].
Investigated was performed to
examine the performance of tool
electrode formed by copper
electroplating on FDM samples.
Two stepped cylindrical
electrodes were prepared and
machining of D2 steel plate was
carried out [56].
Machining performance of FDM
part electroplated with copper
was investigated. The
performance of CE electrode is
compared with a SC electrode of
same outer dimension [57].
Conclusions
Performance study showed that
current is more dominant factor
when compared against voltage
and pulse on time. Main effect
plot was used for determining the
optimal set of parameter setting
for prepared electrode.
Comparison of results with solid
copper tool revealed that the
MRR and TWR obtained using
copper electroplated electrode is
similar to result produced by solid
copper tool.
It was observed that copper
electroplated electrode performs
identical to solid electrode for
each performance measure
studied.
Ease and merits
Metallized thickness of 1.5 mm
achieved on FDM fabricated
parts using simple electroless
process. The performance is also
satisfactory.
Once the metallized layer is worn
out same electrode can be
metalized selectively calculatively
for reuse. The shown process will
reduce the metallization time and
material and significantly
minimizes the cycle time and cost
of the tool.
They conclude that weight of
copper electroplated is less than
solid electrode (less than 1/3rd of
solid electrode) which helps in
easy usage of plated electrodes.
They also proposed that AM
methods are better alternative for
complex shaped which are
difficult to produce using the
traditional machining method
Limitations or shortcomings
Machining is in accordance with
L9 array only and maximum
value at which machining was
performed was 6A. Testing must
be done at higher current to
determine the efficacy of prepared
electrode.
Many advantages of the process
are mentioned however the
dimensional accuracy of
machined hole is still lacking.
Complex electrode profile plating
process may be complex and
accuracy of plated electrode may
vary
8 A. Equbal et al.
solid copper electrodes, according to the literature. According
to the literature, metallization was primarily accomplished
using a simple electroless technique to produce a conductive
coating for AM parts. It was also discovered that the electro-
less technique was extremely slow, thus an in-depth investiga-
tion was conducted into the performance of electroplating on
electroless copper coated FDM parts, as well as the governing
equations for controlling plating quality [4]. The machining
performance of metalized FDM electrodes was shown to be
superior than electrodes generated by other AM process types,
such as SLA and SLS. A critical review has been offered in this
study in order to urge researchers, practitioners, and scientists
to expand their investigations in this direction, as a result of
the restricted number of studies available in this field.
7. Conclusions
In the present research feasibility of the FDM process was
investigated for the production of electrodes for Die-sinking
EDM. Important relating researches were presented and dis-
cussed. The study also tried to discuss the relative merits, ease,
and limitation of proposed methodologies. Analyses of litera-
ture conclude the following important observations:
1. Real-time analysis showed the feasibility of the FDM pro-
cess for the production of EDM electrodes.
2. Comparative studies showed that machining performances
of the metalized electrodes produced by FDM, measured in
terms of MRR, TWR, SR, and dimensional accuracy, were
comparable or better than solid copper electrodes.
3. Electroless metallization is simple and the preferred route
for metalizing the non-conducting electrodes produced by
FDM.
4. Electrodes fabricated by FDM are not only suitable for
machining simple metals and alloys but they can be used
to machining super alloys like Ti-6Al-4V.
5. Although the machining performance showed by FDM
fabricated electrodes were better than the electrodes pro-
duced by SLA and SLS but despite this the FDM related
EDM researches were fewer than SLA and SLS based
EDM studies.
In accordance with the literature-based survey performed
for the production of EDM electrodes using FDM process,
the following important directions are suggested for consider-
ation by researchers in future studies:
i. Other metallization methods like chemical depositions,
vapour depositions, spray metal method, and electro-
forming can be used for metallization of the FDM fab-
ricated electrodes, and machining performances of these
electrodes should be compared with the electrodes met-
allized with electroless and electroplating procedures.
ii. EDM has been performed with electrodes of simple
geometries. Complex cavities can be produced with com-
plex electrode profiles and should be investigated.
iii. It has been noticed that only Equbal et al. [4] have inves-
tigated the machining performance of electrodes pro-
duced by FDM, measured in terms of dimensional
accuracy of the machined cavity. More studies should
be performed to validate the result.
Declaration of Competing Interest
The authors declare that they have no known competing
financial interests or personal relationships that could have
appeared to influence the work reported in this paper.
Acknowledgement
The authors extend their appreciation to the Deanship of Sci-
entific Research at King Khalid University for funding this
work through research groups program under grant number
(RGP. 2/166/42).
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