Metals were deposited using wire-arc spray-on components made by 3D printing with polyvinyl alcohol (PVA), a water-soluble polymer. The polymer was then dissolved, leaving a metal layer whose surface topography was negative to that of the polymer. This is a rapid and low-cost alternative to 3D printing directly using metal, but to succeed it is essential for the sprayed metal to adhere to the polymer substrate. Tests were done in which aluminum and copper were sprayed using a twin-wire arc spray system onto 3D printed coupons, 50 × 50 mm in size, made from PVA, polylactic acid (PLA), and PLA mixed with metal (aluminum, copper) or carbon fiber. Adhesion depended on substrate roughness (minimum 1-2 µm) substrate temperature (above the glass transition temperature but below the melting temperature of the polymer) and minimizing residual stresses due to mismatch of the thermal expansion coefficients of metal and polymer. It was shown that surface features could be made on metal components using this technique. Plates with internal flow passages were made by placing 3D printed PVA parts in channels machined in the plates, spraying metal over the polymer, and then dissolving the polymer.

金属是使用由水溶性聚合物聚乙烯醇 (PVA) 3D 打印制成的电弧喷涂组件沉积的。然后将聚合物溶解，留下一个金属层，其表面形貌与聚合物的形貌相反。这是直接使用金属进行 3D 打印的快速且低成本的替代方案，但要成功，喷涂金属必须粘附在聚合物基板上。测试中使用双丝电弧喷涂系统将铝和铜喷涂到 3D 打印试件上，尺寸为 50 × 50 mm，由 PVA、聚乳酸 (PLA) 和 PLA 与金属（铝、铜）混合制成或碳纤维。附着力取决于基材粗糙度（最小 1-2  µm) 基材温度（高于玻璃化转变温度但低于聚合物的熔化温度）和最小化由于金属和聚合物的热膨胀系数不匹配导致的残余应力。结果表明，使用这种技术可以在金属部件上制作表面特征。具有内部流动通道的板是通过将 3D 打印的 PVA 部件放置在板中加工的通道中，在聚合物上喷涂金属，然后溶解聚合物而制成的。