Process optimization and study of the co-sintering behaviour of Cu-Ni multi-material 3D structures fabricated by spark plasma sintering (SPS)

•The densification behavior of CuCrZr and nickel upon spark plasma sintering is analysed for different sintering conditions.•The difference in sintering behavior of both materials is quantified using the concept of Master Sintering Curves.•A strategy for co-sintering both materials is developed using pressure-dependent master sintering surfaces.•Co-sintered 3D multi-material structures show a density of 99.9% in CuCrZr and 99.8% in Ni and diffuse sound interfaces.