Subtractive + Additive = Hybrid
Ever hear the old adage "You can subtract but you can't add material?"
Well, what if that was no longer true? Working in a machine shop over the years, I cannot tell you how many times we had to scrap a part due to a broken tool or a bad program.
What if you could quickly add material and resume a program or continue with a corrected program? How much would that be worth? What if you could design a part with an internal structure that could not be machined or manufactured using traditional processes?
Well, now it’s possible to simply add a tool to an existing CNC mill or mill turn machine that will be able to add material to a part. This new type of additive manufacturing is called Directed Energy Deposition. The process varies from machine to machine but it is basically comprised of material being jetted into the path of a laser depositing new material on a part in a CNC controlled manner. At first this was designed to be in a stand-alone machine but, as you can see in the video examples below, some very creative individuals have figured out how to add this technology to an existing CNC mill or mill turn machine. So, with a simple tool change, you can now add material to an existing part, repair an old part, or create a new part out of nothing.
With new technology advancements in additive manufacturing coming out every day, the idea of “Zero Point Manufacturing” is becoming an ever increasing reality. This combining of subtractive and additive known as “Hybrid” was a natural next step to bridge the two concepts of manufacturing. This will make it less expensive for machine shops to get into the additive field, reduce waste, and open up business not currently available to them.
Aerospace companies are designing more and more for additive. For example, Air Bus is producing a new plane with over 1,200 additive parts in it. Machine shops, in order to remain competitive, need to be able to quote these types of parts. This technology is a great first step in that direction.
Hybrid LENS 3D Printer with Fadal Vertical Mill
Hybrid Additive and Subtractive manufacturing machine by DMG Mori
3D Tech Evangelist | SuperScanMan | Saving the day with Industrial CT Scanning Analysis | 3D Storytelling | Author & Speaker | Advocate for Smarter, Faster, Better Manufacturing
8 年Great article Chris! Well written. Keep up the great work. Will you be showcasing this hybrid technology at any shows?
Passionate & Resourceful
8 年There are two approaches to hybrid manufacturing; all-in-one systems like the ones mentioned in this article, or a holistic approach with dedicated machines for AM and machining functions (explained in article here: https://goo.gl/XWbYdu) It's not a question of better and worse, it's about using the right approach for the right application. When material must be added to existing structures, retrofitting directed energy deposition tools to a CNC machine center can offer tremendous value. When intricate 3D structures and fine resolution are required, powder bed fusion and post process machining can yield results that can't be achieved by an all-in-one system. Food for thought.
Automation Professional
8 年Optomec out of Albuquerque has been doing this for a number of years
Staff Application Engineer @ Stratasys / NEO
8 年serious I'd love to play with one for a awhile
Quality Engineer
8 年3D printing taken to the real world