L’iMPacT: Low-cost Hybrid Metal 3D Printing and Machining Technology

混合制造(HM)是一个术语，用于描述将加法制造(3D打印-AM)和减法(加工)工艺相结合的工艺，从而在一台机器上实现多个操作。HM工艺结合了这些制造技术的优点，同时弥补了它们的缺点。例如，使用3D打印技术制造的大部分零件都需要进行后处理以改善表面光洁度(例如抛光、铣削等)。另一方面，昂贵部件的再制造需要沉积材料，这是组合HM技术的明显优势。 我们正处于聚合物3D打印领域公认的突破之中。然而，金属的利用具有更大的工业兴趣和意义，具有更大的市场潜力，特别是对艾伯塔省来说。所要求的设备将提高美国大学先进金属制造的能力。目前，优质商业金属打印机的平均价格超过1,000,000美元。3D金属打印机的高资本成本和缓慢的生产速度限制了它们的分布，在教育机构中几乎找不到。 该大学混合制造设施的可用性将为行业合作开辟新的途径，同时也为培养具有不同研究计划的高素质人才(HQP)提供便利，研究项目包括：1)整合先进的金属沉积技术以生产高精度和制造智能化的复杂零件；2)通过刀具路径优化提高产品强度，3)用于测试新鼻药产品的鼻道设计、制造和分析，4)研究：丝束和弧束之间的相互作用；沉积的后续凝固；微观组织的形成；以及部件的最终机械性能。 除了上述项目外，该设备还将被用作艾伯塔省制造公司的测试/示范单位。我们还计划扩大这一设施，以建立一个金属印刷能力中心，并将与加拿大各地的许多其他大学和行业合作。作为研究计划的一部分，我们将对许多产品和集成技术进行评估、产业化和专利申请。 所需设备的供应将推动若干领域的最先进技术，包括：低成本目标的联合加工和3D打印、生产时间更短的再制造、复杂部件的强度增强和部件分析以及未来创新部件的关键合金分析。所要求的设备将加速艾伯塔省经济的多样化，并将补充当地工业日益转向清洁和绿色制造的趋势。

Hybrid Manufacturing (HM) is a term used to describe processes which combine additive manufacturing (3D printing - AM) with subtractive (machining) processes, enabling multiple operations on a single machine. HM processes combine the benefits of each of these manufacturing techniques while offsetting their short comings. For example, the majority of the parts made with 3D printing technology require post-processing to improve the surface finish (e.g. polishing, milling etc.). On the other hand, re-manufacturing of expensive parts requires the deposition of materials, which is a clear advantage of the combined HM technology. We are in the midst of a well-recognized break-through in 3D printing with polymers. However, the utilization of metals is of greater industrial interest and significance and has much more market potential, especially for Alberta. The equipment requested will boost the capabilities of advanced metal manufacturing at the U of A. Currently, the average price for quality commercial metal printers is more than $1,000,000. The high capital cost and slow production rate of 3D metal printers has limited their distribution and there are very few to be found at educational institutions. The availability of hybrid manufacturing facility at the University will open up new ways to collaborate with industries, but also provide easy access to train Highly Qualified Personnel (HQP) with diverse research programs including: 1) Integrating advanced technologies to deposit metals to produce complex parts with high precision and manufacturing intelligence, 2) Product strength enhancement by tool-path optimization, 3) Design, manufacturing and analysis of nasal airway for testing new nasal drug products, and 4) the investigation of: the interactions between wire and arc beam; the subsequent solidification of deposits; the formation of the microstructure; and the final mechanical properties of the components. In addition to the programs mentioned above, the equipment will also be used as a test/demonstration unit for manufacturing companies in Alberta. We are also planning to extend this facility to build a metal printing competence center and will collaborate with many other universities and industries across Canada. As part of the research program we will assess, industrialize and patent many products and integrated technology. The availability of the requested equipment will advances the state-of-the-art technology in a number of areas including: combined machining and 3D printing with low-cost objectives, re-manufacturing with shorter production times, strength enhancement and parts analysis of complex parts and critical alloy analysis for future innovative components. The requested equipment will accelerate the diversification of the Alberta economy and will supplement the growing shift of the local industries towards clean and green manufacturing.