Joeviocoe wrote: How simple (or difficult) would it be to create the entire Anode/crown assembly out of one solid mass of metal? No metal/metal contact surfaces at all? Could any modern fabrication (3d Printing) or rapid prototyping work to build this?
That will probably happen when the optimum design has been finalized. Flexibility in shape, placement and materials is important now in the experimental phase of development.
Soldering, brazing and welding of the elements would precede making and machining castings in a foundry.