Purpose – This paper aims to investigate the effects on material properties of layer-by-layer application of pressure during fabrication of polymeric parts by additive manufacturing (AM). Although AM, also known popularly as 3D printing, has set a new standard for ease of use and minimal restraint on geometric complexity, the mechanical part properties do not generally compare with conventional manufacturing processes. Contrary to other types of polymer processing, AM systems do not normally use (in-process) pressure during part consolidation. Design/methodology/approach – Tensile specimens were produced in Somos 201 using conventional laser sintering (LS) and selective laser printing (SLP) – a process under development in the UK, which incorporates the use of pressure to assist layer consolidation. Findings – Mechanical testing demonstrated the potential to additively manufacture parts with significantly improved microstructure and mechanical properties which match or exceed conventional processing. For example, the average elongation at break and ultimate tensile strength of a conventionally laser-sintered thermoplastic elastomer (Somos 201) increased from 136 ± 28 per cent and 4.9 ± 0.4 MPa, to 513 ± 35 per cent and 10.4 ± 0.4 MPa, respectively, when each layer was fused with in-process application of pressure (126 ± 9 kPa) by SLP. Research limitations/implications – These results are based on relatively small sample size, but despite this, the trends observed are of significant importance to the elimination of voids and porosity in polymeric parts. Practical implications – Layerwise application of pressure should be investigated further for defect elimination in AM. Originality/value – This is the first study on the effects of layerwise application of pressure in combination with area-wide fusing.
The advent of laser technology has been a key enabler for industrial 3D printing, known as Additive Manufacturing (AM). Despite its commercial success and unique technical capabilities, laser-based AM systems are not yet able to produce parts with the same accuracy and surface finish as CNC machining. To enable the geometry and material freedoms afforded by AM, yet achieve the precision and productivity of CNC machining, hybrid combinations of these two processes have started to gain traction.To achieve the benefits of combined processing, laser technology has been integrated into mainstream CNC machineseffectively repurposing them as hybrid manufacturing platforms. This paper reviews how this engineering challenge has prompted beam delivery innovations to allow automated changeover between laser processing and machining, using standard CNC tool changers. Handling laser-processing heads using the tool changer also enables automated change over between different types of laser processing heads, further expanding the breadth of laser processing flexibility in a hybrid CNC. This paper highlights the development, challenges and future impact of hybrid CNCs on laser processing.
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