Combined Laser Additive Manufacturing and Subtractive Surface Finishing (CLASS)

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Laser powder bed fusion (PBF) is an emerging manufacturing approach to produce net shapesand functional products directly from computer aided three dimensional designs. The parts arebuilt by the consecutive application and consolidation of material layers. In order to becomemore widely accepted within manufacturing, there are still considerable hardware associatedissues which need to be resolved including but not restricted to; residual stress, surfacetexture and methodologies for surface finishing, these problems are exacerbated as theprocess gets faster and is applied to larger parts. The ability to capture in -- process data bydigital integration will further validate the acceptance of the AM process in the production ofparts which are controlled by regulatory standards, where process records are required.The aim of this project is to produce a metal AM machine platform, the subsystems of which arescalable in future to meter class, which is capable of reducing the residual stresses developedduring the AM build, and that will perform in process non-contact finishing on parts as they arebuilt. Multiple machines will also be digitally connected and monitored via sensors for real-timeinsights across a cohort of globally connected manufacturing facilities.