b'Three-DimensionalNovel technology enables multi-scale manufacturing of complex components Electrochemicaland materials with low cost and low waste.Manufacturing and Sensing T he U.S. manufacturing sector uses 25% of the nations energy and has an annual energy bill of more than $130 billion. Advancements in manufacturing impact the energy efficiency of products used throughout the economy. Innovative manufacturing has great potential to strengthen the U.S. economy and national security, produce high income jobs, and generate technological innovationdriving long-term economic prosperity and growth. Currently, a range of advanced manufacturing technologies are under investigation for different applications. This research developed a unique three-dimensional electrochemical manufacturing and sensing (3DEMS) technology for primary advanced materials manufacturing application. It enables the fabrication of TOTAL APPROVED AMOUNT:components with complicated shapes and varying dimensions, as well as controls $1,081,850 over 3 years of their chemical form, composition, and microstructures at different scales (from atomic to macro). This technology manufactures under relatively milder conditions PROJECT NUMBER:compared to traditional technologies. The 3DEMS is also a potential sensing 19A39-130 technology for the online monitoring of manufacturing processes and remote PRINCIPAL INVESTIGATOR:detection of hazardous contaminants and can also be used to fabricate advanced Junhua Jiang sensors. Furthermore, the 3DEMS is potentially scalable for mass production or can be minimized for nano-to-micro/macro machining. Specific scientific and technical CO-INVESTIGATORS: accomplishments from the research include: (1) integration of a full 3DEMS system; Congjian Wang, INL (2) manufacturing of surrogate aluminum and aluminum-zirconium alloys with Prabhat Tripathy, INL even gradient microstructures through the development of novel electrochemical Robert Mariani, INL processes; (3) advanced manufacturing of nuclear coatings; (4) atom irradiation for Haiyan Zhao, University of Idaho accelerated evaluation of nuclear fuels and materials; (5) electrolytic metal-atoms Yaqiao Wu, Boise State University enabled etching and nanostructures/ heterostructures; and (6) electrochemical COLLABORATOR: sensing of simulated fission products.Feng Research Labs, LLC(a) (b) (c)Scanning electron microscope image of (a) porous aluminum on copper, (b) aluminum-zirconium on copper, and (c) etched polycrystalline palladium.95'