Low cost integration of additive and subtractive processes for hybrid layered manufacturing

Karunakaran, K. P.; Suryakumar, S.; Pushpa, Vishal; Akula, Sreenathbabu

doi:10.1016/j.rcim.2010.03.008

Cited by 318 publications

(163 citation statements)

References 25 publications

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“…The surface finish was also controlled, unlike individual NPDS or AFN printing systems. Traditionally, hybrid processes have been defined as a combination of techniques acting simultaneously in a single processing area, i.e., laser-assisted machining (LAM) [80,81]. However, following recent process improvements, this definition has broadened to include configurations in which the advantages of more than two processes are integrated [82].…”

Section: Same Scale In Width and Heightmentioning

confidence: 99%

Hybrid 3D printing by bridging micro/nano processes

Yoon

Jang

Kim

et al. 2017

J. Micromech. Microeng.

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The aim of this work was to develop a novel hybrid manufacturing method for nanoscale three-dimensional (3D) printing with multi-material capabilities. 3D structuring methods at the micro/nanoscale are major goals of various engineering fields, and much work has been carried out to improve the minimum feature size, geometrical complexity, and material selection. With the aim of nanoscale multimaterial printing, a hybrid process was reported with an integrated nanoparticle deposition system (NPDS) and focused ion beam (FIB) system; however this process has limitations in terms of surface roughness and control over the layer thickness, as well as with the process scale, and furthermore, lack of sacrificial layers.In this dissertation, a novel hybrid process is described, which combines aerodynamically focused nanoparticle (AFN) printing, micro-machining and focused ion beam (FIB) milling. AFN printing is based on NPDS, and micromachining was used for local planarization. In addition to these processes, spincoating was used to fabricate sacrificial layers. By bridging these different II micro/nanoscale processes, the resulting hybrid process can address the limitations of the individual processes.To create the hybrid process, each process was investigated to enable compatibility. With the AFN printing system, the surface morphology of a detached substrate was observed, and the bonding mechanism between the substrate and nanoparticles was investigated. A novel printing strategy was identified to reduce the scale of the process. With the micro-machining system, different tool geometries were investigated. Complex geometries inspired by conventional-scale tools were implemented on the micro-scale, and their effects were investigated. With the FIB system, material re-deposition phenomena were investigated to reduce defects that occur during ion sputtering. A novel path-generation strategy was identified and investigated for different scanning paths.Process capability is discussed using fabrication examples and functional applications. The novel hybrid process represents a significant advance in the state of the art, and enables far improved process scales or dimensional degree of freedom, without losing the advantages of broad choice of materials.3D-pinted micro bi-material cantilevers were fabricated as a thermal actuator.The mechanical and thermal properties of the structure were investigated using an in-situ measurement system, and irregular thermal phenomena were analyzed. It is expected that these in-situ measurements of the 3D printed microstructure will contribute to materials research.Various 3D structures can be fabricated using the process described here from a range of metal/ceramic inorganic materials, including polymers. In particular, it is expected that the process will contribute to the area of customized nanoscale structuring, with potential applications in medical treatments. It is also expected that this work will contribute to further improvements in manufacturing technology by combining different m...

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Section: Same Scale In Width and Heightmentioning

confidence: 99%

Hybrid 3D printing by bridging micro/nano processes

Yoon

Jang

Kim

et al. 2017

J. Micromech. Microeng.

View full text Add to dashboard Cite

show abstract

“…For example, NASA's Langley Research Center, Houston and Johnson Space Center, Hampton) [7]. In this case, the electron beam is used as an energy source for melting of the fed wire in a vacuum medium.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

“…In this case, the electron beam is used as an energy source for melting of the fed wire in a vacuum medium. This technology was demonstrated on aluminum and titanium alloys of interest for aerospace applications [7]. There is a possibility to use alloys based on nickel and iron.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

Analysis of the current state of additive welding technologies for manufacturing volume metallic products (review)

Peleshenko

Korzhyk

Voitenko

et al. 2017

EEJET

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“…Studies have investigating novel combinations of manufacturing processes including additive and subtractive [3], subtractive and transformative [4] and additive and transformative [5]. There is growing industrial and academic interest and the number of commercial hybrid additive and subtractive processes has significantly increased since the late 2000s [6].…”

Section: Hybrid Manufacturing Definitionmentioning

confidence: 99%

A decision support methodology for embodiment design and process chain selection for hybrid manufacturing platforms

Gleadall

Vladov

Segal

et al. 2016

Int J Adv Manuf Technol

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This paper presents a methodology for the transformation of a product concept into a detailed design and manufacturing process chain for hybrid manufacturing platforms. Hybrid platforms offer new capabilities and opportunities for product design. However, they require high levels of process expertise for effective design and effective process selection. Design for hybrid manufacture is challenging as there is a requirement to understand a number of technologies, which may be highly varied. To address this challenge, a knowledgebased decision-support system developed in this paper enables manufacturing expertise to be integrated into procedures for product design and process chain selection. This formalised numerical methodology is able to consider a wider range of varied manufacturing processes than any previous study. A feature-based design method is developed, which guides the designer towards an optimised product design during the embodiment design phase, and a process-chain selection program is utilised to enable the effective analysis of a product design based on product evaluation criteria. The methodology has been successfully applied to the design of an LED product with internal geometries and electronics.A decision-support methodology for embodiment design and process chain selection for hybrid manufacturing platforms 2 Key words:Design for manufacture, process chain selection, hybrid manufacture, feature-based design, decisionsupport. Acknowledgements:The research leading to these results has received funding from the European Union Seventh Framework Programme (FP7/2007(FP7/ -2013 under grant agreement number 314580.

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Low cost integration of additive and subtractive processes for hybrid layered manufacturing

Cited by 318 publications

References 25 publications

Hybrid 3D printing by bridging micro/nano processes

Hybrid 3D printing by bridging micro/nano processes

Analysis of the current state of additive welding technologies for manufacturing volume metallic products (review)

A decision support methodology for embodiment design and process chain selection for hybrid manufacturing platforms

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