Title (150 characters) Metal hybrid rapid manufacture for prototyping precision parts

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- Prototyping precision parts from metal can be very expensive and post processingadds a significant delay to lead times.- Iterative designs amplify this cost and time.- An example of this is the generation of metallic formers used in the SuperconductingMagnets Division research team at CERN.o Each magnet may require multiple prototype formers before a design isfinalised.o These formers are produced from stainless steel using Selective LaserSintering (SLS) and then requiring significant post-processing. This includesmachining, surface treatment and then joining (laser welding) of smaller subparts to produce the full part.- Hybrid manufacture combines subtractive and additive manufacturing, reducing postprocessing and allowing the modification of previously manufactured parts.- The use of a Direct Laser Deposition (DLD) system could reduce raw material use,machine cost, and allow integration with a subtractive manufacturing process.- This technique could both simplify and reduce the cost and time to iterate prototypesof precision parts from metal.- This research proposal recommends the investigation of a metal hybrid rapidprototyping methodology; combining both additive and subtractive manufacturingmethods to reduce manufacturing time and production costs of precision parts.- Tightly coupled (hybrid) manufacture may also offer additional design freedoms thatare not possible through subtractive or additive in isolation.