Hybrid Direct Manufacturing Production

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The research objective of this award is to understand the relationships and interactions when combining additive and then subtractive direct manufacturing techniques so that the sequential combination yields the advantages of both production techniques without incurring significant disadvantages. Two specific objectives are: 1) To identify the part geometry inaccuracy and shrinkage in order to establish material allowance during additive processing, and 2) To identify and create mathematical and physical models for setup to account for location error due to the nature of direct metal fabrication surfaces. If successful, this work will provide a rapid capability to make parts with complex freeform geometries as provided by function free-form additive systems, while providing exacting tolerance control and material properties, as provided by computer numerically controlled machining by using these processes sequentially and automatically. This research will lead to a new technology that would create service parts and prototypes for next-generation complex mechanical part systems with the specified material properties, to the exacting tolerances and advanced geometries as desired, and do so in an automated manner with little or no human intervention required.