Development of a Low-Cost Electrochemical Machining Laboratory Demonstrator for Engineering Education

This paper presents the design and development of a low-cost, safe, and portable electrochemical machining (ECM) demonstrator for engineering education. The integration of advanced manufacturing techniques within higher education institutions is becoming increasingly important to ensure that graduates develop the skills and knowledge required to meet the needs of modern manufacturing industries. Electrochemical machining is a non-traditional process capable of producing complex geometries from hard-to-machine materials without tool wear occurring; however, its inclusion in undergraduate teaching as a physical laboratory demonstration is limited due to the high cost and safety considerations of industrial-scale systems. To address this, a compact and cost-effective ECM demonstrator was designed and constructed using accessible, safe materials and low-voltage operation. The demonstrator’s technical performance was verified experimentally, and its educational value evaluated through alignment with course intended learning outcomes (ILOs) and laboratory teaching objectives. The results confirmed that the demonstrator effectively illustrated key ECM principles, enabling students to link theoretical understanding with practical application. This study demonstrates that a low-cost ECM system can enhance the delivery of advanced manufacturing education and support the development of hands-on, industry-relevant skills.