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Microtextured surfaces, particularly circular micropattern, significantly enhance the function and performance of microfabricated devices and engineering parts. A distinctive and inventive concept of maskless microelectrochemical jet machining (EJM) is utilized for producing the microcircular pattern over large area. In this research work, an advanced concept, i.e. maskless micro-EJM is presented to produce the microtextures on large area using the reusable masked tool movement strategy on stainless steel. One masked patterned tool can fabricate many high-quality micropatterned samples over large area using the tool movement strategy. High-pressure electrolyte flow through textured tool is developed to acquire the high-quality microtextures with controlled dimensions. The machining consequence of substantial input parameters, i.e. IEG, flow rate and frequency on microdimpled characteristics such as MRR, overcut, depth, and  Rais explored. Microdimples of 5.3 mg/min MRR, 20.07 µm overcut, 13.5 µm depth, and 0.0601 µm surface roughness and 5.29 cm 2  machining area are successfully fabricated using the reusable masked tool. The present study confirms that it is achievable to acquire the large area microtexturing using this innovative technique.

Micro-electrochemical jet machining of large area microtexturing with tool movement strategy