Finite element analysis of a mask-less electrochemical texturing (MECT) method on metallic surface

A simple and economical method, termed 'mask-less electrochemical texturing' (MECT), is explored to fabricate large-area microstructures on the metallic surface. The method allows for the cathode tool, on which the microstructures can be obtained by mask patterning technology, to be used for molding for multiple runnings, so the process avoids the necessity of masks on individual metal sheet. Based on the characteristics of the MECT method, a 2D model is built to analyze the process to predict and optimize the relationship of the current density distribution at the anode surface with the different photoresist mask parameters and machining gap. With the optimized parameters, the model is then used to evolve the shape of microstructures in the anode in order to obtain the prescribed textured metal surface.