Defect Free Hybrid Additive Manufacturing

添加剂制造允许创造高度定制化和个性化的产品，然而，这一优势也带来了检查和合格部件的挑战。与传统的大规模制造相比，添加制造不允许破坏性测试，并且由于部件之间的固有差异，它难以适应统计过程控制方法。额外的、不正确的或遗漏的材料放置造成的缺陷可能会导致零件不具备所需的机械完整性、性能和可靠性。最终，这种产量损失会导致生产成本和时间的增加，从而限制了添加剂制造的优势。该项目旨在解决这一问题，通过使用计算机控制的混合3D打印技术来实现无缺陷生产，该技术结合了加法沉积和减法处理。实时监控工艺将允许在创建层时识别缺陷。然后，可以通过减法操作重新加工这一层，并在正确的加工条件下重新沉积。由于潜在的广泛受益者和工程陶瓷生产的挑战，本专业将集中于这一应用领域。本课程的目标是：1)检查不同的成像技术，以确定每层的最佳检查方法。2)采用图像分析方法对缺陷进行量化。3)发展机器学习，提高定制零件的缺陷识别能力。4)生成允许重新加工特定层的刀具路径规划操作。5)无缺陷陶瓷件的生产示范。

Additive Manufacturing allows the creation of highly customised and personalised products, however, this advantage also creates challenges with inspecting and qualifying parts. Compared with traditional mass manufacturing, additive manufacturing does not allow destructive testing and due to the inherent differences between parts, it struggles to accommodate statistical process control methods. Defects from additional, incorrect or missing material placement can result in parts that do not have the required mechanical integrity, performance and reliability. Ultimately this yield loss restricts the advantages of Additive Manufacturing by causing wastage alongside increased production cost and time. This studentship seeks to overcome this issue to enable defect-free production through the use of computer-controlled hybrid 3D Printing which combines additive deposition and subtracting processes. Monitoring the process in real-time will allow the identification of defects when creating a layer. This layer can then be re-worked through a subtractive operation and redeposited with the correct processing conditions. Due to the potential widespread beneficiaries and challenges with producing engineered ceramics, this studentship will focus on this application area. The objectives of this studentship are: 1) Examination of different imaging techniques to determine the optimal inspection methods per layer. 2) Using image analysis methods to quantify defects. 3) Develop machine learning to improve defect identification for bespoke parts. 4) Generation of toolpath planning operations that allow reworking of a specific layer. 5) Demonstrating the production of defect-free ceramic parts.