Journal articles: 'Hybrid Metal and Polymer Additive Manufacturing'

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Silva, Miguel Reis, Jorge Domingues, João Costa, Artur Mateus, and Cândida Malça. "Study of Metal/Polymer Interface of Parts Produced by a Hybrid Additive Manufacturing Approach." Applied Mechanics and Materials 890 (April 2019): 34–42. http://dx.doi.org/10.4028/www.scientific.net/amm.890.34.

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The additive manufacturing of multimaterial parts, e.g. metal/plastic, with functional gradients represents for current market demands a great potential of applications [1]. Metal Polymer parts combine the good mechanical properties of the metals with the low weight characteristics, good impact strength, good vibration and sound absorption of the polymers. Nevertheless, the coupling between metal and polymers is a great challenge since the processing factors for each one of them are very different. In addition, a system that makes the hybrid processing - metal/polymer - using only one operation is unknown [2, 3]. To overcome this drawback, a hybrid additive manufacturing system based on the additive technologies of SLM and SL was recently developed by the authors. The SLM and SL techniques joined enabling the production of a photopolymerization of the polymer in the voids of a 3D metal mesh previously produced by SLM [4]. The purpose of this work is the study on the metal/polymer interface of hybrid parts manufactured from the hybrid additive manufacturing system [5]. For this, a core of tool steel (H13) and two different types of photo-polymers: one elastomeric (BR3D-DL-Flex) and another one rigid (BR3D-DL-Hard) are considered. A set of six samples for each one of metal core/polymer combination was manufactured and submitted to tensile tests.

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Setter, Robert, Jan Hafenecker, Richard Rothfelder, Sebastian-Paul Kopp, Stephan Roth, Michael Schmidt, Marion Merklein, and Katrin Wudy. "Innovative Process Strategies in Powder-Based Multi-Material Additive Manufacturing." Journal of Manufacturing and Materials Processing 7, no. 4 (July 24, 2023): 133. http://dx.doi.org/10.3390/jmmp7040133.

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Multi-material additive manufacturing (AM) attempts to utilize the full benefits of complex part production with a comprehensive and complementary material spectrum. In this context, this research article presents new processing strategies in the field of polymer- and metal-based multi-material AM. The investigation highlights the current progress in powder-based multi-material AM based on three successfully utilized technological approaches: additive and formative manufacturing of hybrid metal parts with locally adapted and tailored properties, material-efficient AM of multi-material polymer parts through electrophotography, and the implementation of UV-curable thermosets within the laser-based powder bed fusion of plastics. Owing to the complex requirements for the mechanical testing of multi-material parts with an emphasis on the transition area, this research targets an experimental shear testing set-up as a universal method for both metal- and polymer-based processes. The method was selected based on the common need of all technologies for the sufficient characterization of the bonding behavior between the individual materials.

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Falck, R., S. M. Goushegir, J. F. dos Santos, and S. T. Amancio-Filho. "AddJoining: A novel additive manufacturing approach for layered metal-polymer hybrid structures." Materials Letters 217 (April 2018): 211–14. http://dx.doi.org/10.1016/j.matlet.2018.01.021.

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Tosto, Claudio, Jacopo Tirillò, Fabrizio Sarasini, and Gianluca Cicala. "Hybrid Metal/Polymer Filaments for Fused Filament Fabrication (FFF) to Print Metal Parts." Applied Sciences 11, no. 4 (February 5, 2021): 1444. http://dx.doi.org/10.3390/app11041444.

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The exploitation of mechanical properties and customization possibilities of 3D printed metal parts usually come at the cost of complex and expensive equipment. To address this issue, hybrid metal/polymer composite filaments have been studied allowing the printing of metal parts by using the standard Fused Filament Fabrication (FFF) approach. The resulting hybrid metal/polymer part, the so called “green”, can then be transformed into a dense metal part using debinding and sintering cycles. In this work, we investigated the manufacturing and characterization of green and sintered parts obtained by FFF of two commercial hybrid metal/polymer filaments, i.e., the Ultrafuse 316L by BASF and the 17-4 PH by Markforged. The Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectrometry (EDS) analyses of the mesostructure highlighted incomplete raster bonding and voids like those observed in conventional FFF-printed polymeric structures despite the sintering cycle. A significant role in the tensile properties was played by the building orientation, with samples printed flatwise featuring the highest mechanical properties, though lower than those achievable with standard metal additive manufacturing techniques.

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Ozlati, A., M. Movahedi, M. Tamizi, Z. Tartifzadeh, and S. Alipour. "An alternative additive manufacturing-based joining method to make Metal/Polymer hybrid structures." Journal of Manufacturing Processes 45 (September 2019): 217–26. http://dx.doi.org/10.1016/j.jmapro.2019.07.002.

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Silva, M., A. Mateus, D. Oliveira, and C. Malça. "An alternative method to produce metal/plastic hybrid components for orthopedics applications." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 231, no. 1-2 (August 20, 2016): 179–86. http://dx.doi.org/10.1177/1464420716664545.

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The demand for additive processes that provide components with high technological performance became overriding regardless of the application area. For medical applications, the orthopedics field—multimaterial orthoses and splints—can clearly benefit from direct additive manufacturing using a hybrid process instead of the traditional handmade manufacturing, which is slow, expensive, inaccurate, and difficult to reproduce. The ability to provide faster better orthoses, using innovative services and technologies, resulting in lower recovery times, reduced symptoms, and improved functional capacity, result in a significant impact on quality of life and the well-being of citizens. With these purposes, this work presents an integrate methodology, that includes the tridimensional (3D) scanning, 3D computer-aided design modeling, and the direct digital manufacturing of multimaterial orthoses and splints. Nevertheless, additive manufacturing of components with functional gradients, multimaterial components, e.g. metal/plastic is a great challenge since the processing factors for each one of them are very different. This paper proposes the addition of two advanced additive manufacturing technologies, the selective laser melting and the stereolithography, enabling the production of a photopolymerization of the polymer in the voids of a 3D metal mesh previously produced by selective laser melting. Based on biomimetic structures concept, this mesh is subject to a previous design optimization procedure in order to optimize its geometry, minimizing the mass involved and evidencing increased mechanical strength among other characteristics. A prototype of a hybrid additive manufacturing device was developed and its flexibility of construction, geometrical freedom, and different materials processability is demonstrated through the case study—arm orthosis—presented in this work.

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Chueh, Yuan-Hui, Xiaoji Zhang, Jack Chun-Ren Ke, Qian Li, Chao Wei, and Lin Li. "Additive manufacturing of hybrid metal/polymer objects via multiple-material laser powder bed fusion." Additive Manufacturing 36 (December 2020): 101465. http://dx.doi.org/10.1016/j.addma.2020.101465.

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Silva, M., R. Felismina, A. Mateus, P. Parreira, and C. Malça. "Application of a Hybrid Additive Manufacturing Methodology to Produce a Metal/Polymer Customized Dental Implant." Procedia Manufacturing 12 (2017): 150–55. http://dx.doi.org/10.1016/j.promfg.2017.08.019.

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Barakat, Ali A., Basil M. Darras, Mohammad A. Nazzal, and Aser Alaa Ahmed. "A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures." Polymers 15, no. 1 (December 31, 2022): 220. http://dx.doi.org/10.3390/polym15010220.

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Metal–polymer hybrid structures are becoming desirable due to their wide range of applications in the automotive, aerospace, biomedical and construction industries. Properties such as a light weight, high specific strength, and design flexibility along with the low manufacturing costs of metal–polymer hybrid structures make them widely attractive in several applications. One of the main challenges that hinders the widespread utilization of metal–polymer hybrid structures is the challenging dissimilar joining of metals to polymers. Friction stir welding (FSW) shows a promising potential in overcoming most of the issues and limitations faced in the conventional joining methods of such structures. Several works in the literature have explored the FSW of different metal-to-polymer combinations. In some of the works, the joints are examined based on processing parameter optimization, microstructural characteristics, and mechanical performances. It is, therefore, important to summarize the findings of these works as a means of providing a reference to researchers to facilitate further research on the utilization of FSW in joining metals to polymers. Thus, this work aims to present a comprehensive technical review on the FSW technique for joining metals to polymers by reviewing the reported literature findings on the impact of materials, tools, process parameters, and defects on the strength and microstructure of the produced joints. In addition, this work reviews and presents the latest practices aiming to enhance the metal–polymer joint quality that have been reported in the literature.

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Fernandez, Ellen, Mariya Edeleva, Rudinei Fiorio, Ludwig Cardon, and Dagmar R. D’hooge. "Increasing the Sustainability of the Hybrid Mold Technique through Combined Insert Polymeric Material and Additive Manufacturing Method Design." Sustainability 14, no. 2 (January 13, 2022): 877. http://dx.doi.org/10.3390/su14020877.

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To reduce plastic waste generation from failed product batches during industrial injection molding, the sustainable production of representative prototypes is essential. Interesting is the more recent hybrid injection molding (HM) technique, in which a polymeric mold core and cavity are produced via additive manufacturing (AM) and are both placed in an overall metal housing for the final polymeric part production. HM requires less material waste and energy compared to conventional subtractive injection molding, at least if its process parameters are properly tuned. In the present work, several options of AM insert production are compared with full metal/steel mold inserts, selecting isotactic polypropylene as the injected polymer. These options are defined by both the AM method and the material considered and are evaluated with respect to the insert mechanical and conductive properties, also considering Moldex3D simulations. These simulations are conducted with inputted measured temperature-dependent AM material properties to identify in silico indicators for wear and to perform cooling cycle time minimization. It is shown that PolyJetted Digital acrylonitrile-butadiene-styrene (ABS) polymer and Multi jet fusioned (MJF) polyamide 11 (PA11) are the most promising. The former option has the best durability for thinner injection molded parts, and the latter option the best cooling cycle times at any thickness, highlighting the need to further develop AM options.

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Falck, Rielson, Jorge F. dos Santos, and Sergio T. Amancio-Filho. "Microstructure and Mechanical Performance of Additively Manufactured Aluminum 2024-T3/Acrylonitrile Butadiene Styrene Hybrid Joints Using an AddJoining Technique." Materials 12, no. 6 (March 14, 2019): 864. http://dx.doi.org/10.3390/ma12060864.

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AddJoining is an emerging technique that combines the principles of the joining method and additive manufacturing. This technology is an alternative method to produce metal–polymer (composite) structures. Its viability was demonstrated for the material combination composed of aluminum 2024-T3 and acrylonitrile butadiene styrene to form hybrid joints. The influence of the isolated process parameters was performed using the one-factor-at-a-time approach, and analyses of variance were used for statistical analysis. The mechanical performance of single-lap joints varied from 910 ± 59 N to 1686 ± 39 N. The mechanical performance thus obtained with the optimized joining parameters was 1686 ± 39 N, which failed by the net-tension failure mode with a failure pattern along the 45° bonding line. The microstructure of the joints and the fracture morphology of the specimens were studied using optical microscopy and scanning electron microscopy. From the microstructure point of view, proper mechanical interlocking was achieved between the coated metal substrate and 3D-printed polymer. This investigation can be used as a base for further improvements on the mechanical performance of AddJoining hybrid-layered applications.

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Hertle, Sebastian, Tobias Kleffel, Andreas Wörz, and Dietmar Drummer. "Production of polymer-metal hybrids using extrusion-based additive manufacturing and electrochemically treated aluminum." Additive Manufacturing 33 (May 2020): 101135. http://dx.doi.org/10.1016/j.addma.2020.101135.

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Syrlybayev, Daniyar, Aidana Seisekulova, Didier Talamona, and Asma Perveen. "The Post-Processing of Additive Manufactured Polymeric and Metallic Parts." Journal of Manufacturing and Materials Processing 6, no. 5 (October 4, 2022): 116. http://dx.doi.org/10.3390/jmmp6050116.

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The traditional manufacturing industry has been revolutionized with the introduction of additive manufacturing which is based on layer-by-layer manufacturing. Due to these tool-free techniques, complex shape manufacturing becomes much more convenient in comparison to traditional machining. However, additive manufacturing comes with its inherent process characteristics of high surface roughness, which in turn effect fatigue strength as well as residual stresses. Therefore, in this paper, common post-processing techniques for additive manufactured (AM) parts were examined. The main objective was to analyze the finishing processes in terms of their ability to finish complicated surfaces and their performance were expressed as average surface roughness (Sa and Ra). The techniques were divided according to the materials they applied to and the material removal mechanism. It was found that chemical finishing significantly reduces surface roughness and can be used to finish parts with complicated geometry. Laser finishing, on the other hand, cannot be used to finish intricate internal surfaces. Among the mechanical abrasion methods, abrasive flow finishing shows optimum results in terms of its ability to finish complicated freeform cavities with improved accuracy for both polymer and metal parts. However, it was found that, in general, most mechanical abrasion processes lack the ability to finish complex parts. Moreover, although most of post-processing methods are conducted using single finishing processes, AM parts can be finished with hybrid successive processes to reap the benefits of different post-processing techniques and overcome the limitation of individual process.

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Falck, Rielson, and Sergio T. Amancio-Filho. "The Influence of Coating and Adhesive Layers on the Mechanical Performance of Additively Manufactured Aluminum–Polymer Hybrid Joints." Metals 13, no. 1 (December 23, 2022): 34. http://dx.doi.org/10.3390/met13010034.

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AddJoining technique has been recently introduced to produce metal–polymer composite hybrid layered structures. The methodology combines the principles of joining and polymeric additive manufacturing. This paper presents three AddJoining process-variants investigated and demonstrated for the material combination aluminum 2024-T3 and acrylonitrile butadiene styrene to form hybrid single lap joints. The microstructure and mechanical performance were assessed. The process variant using heating control showed the ultimate lap shear force of 1.2 ± 0.05 kN and displacement at a break of 1.21 ± 0.16 mm as a result of strong bonding formation at the interface of the hybrid joints. For instance, the other two process variants tested (with epoxy adhesive, and with thin-acrylonitrile butadiene styrene (ABS) coating layer applied on the metal) presented reduced mechanical performance in comparison to process variant using heating control, namely approximately 42% and 8.3%, respectively. The former had a mixed adhesive–cohesive failure due to the lower bonding performance between the adhesive and ABS printed layers. The latter displayed a slight decrease in force in comparison to heat-control specimens. This could be explained by the presence of micro-voids formed by solvent evaporation at the ABS coating layer during AddJoining.

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Moritz, Juliane, Philipp Götze, Tom Schiefer, Lukas Stepien, Annett Klotzbach, Jens Standfuß, Elena López, Frank Brückner, and Christoph Leyens. "Additive Manufacturing of Titanium with Different Surface Structures for Adhesive Bonding and Thermal Direct Joining with Fiber-Reinforced Polyether-Ether-Ketone (PEEK) for Lightweight Design Applications." Metals 11, no. 2 (February 4, 2021): 265. http://dx.doi.org/10.3390/met11020265.

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Hybrid joints consisting of metals and fiber-reinforced polymer composites exhibit highly desirable properties for many lightweight design applications. This study investigates the potential of additively manufactured surface structures for enhancing the bond strength of such joints in comparison to face milled and laser structured surfaces. Titanium samples with different surface structures (as-built surface, groove-, and pin-shaped structures) were manufactured via electron beam melting and joined to carbon fiber-reinforced polyether-ether-ketone (PEEK) via adhesive bonding and thermal direct joining, respectively. Bond strength was evaluated by tensile shear testing. Samples were exposed to salt spray testing for 1000 h for studying bond stability under harsh environmental conditions. The initial tensile shear strengths of the additively manufactured samples were competitive to or in some cases even exceeded the values achieved with laser surface structuring for both investigated joining methods. The most promising results were found for pin-shaped surface structures. However, the hybrid joints with additively manufactured structures tended to be more susceptible to degradation during salt spray exposure. It is concluded that additively manufactured structures can be a viable alternative to laser surface structuring for both adhesive bonding and thermal direct joining of metal-polymer hybrid joints, thus opening up new potentials in lightweight design.

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Murchio, Simone, Matteo Benedetti, Anastasia Berto, Francesca Agostinacchio, Gianluca Zappini, and Devid Maniglio. "Hybrid Ti6Al4V/Silk Fibroin Composite for Load-Bearing Implants: A Hierarchical Multifunctional Cellular Scaffold." Materials 15, no. 17 (September 5, 2022): 6156. http://dx.doi.org/10.3390/ma15176156.

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Despite the tremendous technological advances that metal additive manufacturing (AM) has made in the last decades, there are still some major concerns guaranteeing its massive industrial application in the biomedical field. Indeed, some main limitations arise in dealing with their biological properties, specifically in terms of osseointegration. Morphological accuracy of sub-unital elements along with the printing resolution are major constraints in the design workspace of a lattice, hindering the possibility of manufacturing structures optimized for proper osteointegration. To overcome these issues, the authors developed a new hybrid multifunctional composite scaffold consisting of an AM Ti6Al4V lattice structure and a silk fibroin/gelatin foam. The composite was realized by combining laser powder bed fusion (L-PBF) of simple cubic lattice structures with foaming techniques. A combined process of foaming and electrodeposition has been also evaluated. The multifunctional scaffolds were characterized to evaluate their pore size, morphology, and distribution as well as their adhesion and behavior at the metal–polymer interface. Pull-out tests in dry and hydrated conditions were employed for the mechanical characterization. Additionally, a cytotoxicity assessment was performed to preliminarily evaluate their potential application in the biomedical field as load-bearing next-generation medical devices.

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Saptaji, Kushendarsyah, Dindamilenia Choirunnisa Hardiyasanti, Muchammad Fachrizal Ali, Raffy Frandito, and Tiara Kusuma Dewi. "Potential Applications of Hydroxyapatite-Mineralized-Collagen Composites as Bone Structure Regeneration: a Review." JOURNAL OF SCIENCE AND APPLIED ENGINEERING 5, no. 1 (March 16, 2022): 33. http://dx.doi.org/10.31328/jsae.v5i1.3577.

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The composites materials are known for their flexibility due to the combinations of two or three different materials and manipulation of their compositions. The advantage offered by composite materials make it suitable for biomedical applications especially to be used for implants. There are three types of composites biocompatible materials namely Metal Matrix Composite (MMC), Ceramic Matrix Composite (CMC) and Polymer Matrix Composite (PMC). In order to produce the biocompatible composite materials, various manufacturing processes can be performed. The manufacturing processes of MMCs are stir casting and powder metallurgy; the typical manufacturing process for CMCs is powder metallurgy; and 3-D printing by synthesizing and cross-linking the networks is used for fabricating PMCs. One of the promising biocompatible composites is Hydroxyapatite Mineralized Collagen (HMC). The HMC is used to create bone scaffold in bone regeneration process. The suggested manufacturing process for HMC is hybrid process which collaborate Additive Manufacturing and CNC Machining. In this paper, the HMC is reviewed especially related with its properties, fabrication method, and existed experimentation. In addition, the three types of biocompatible composites are also discussed on the applications and its manufacturing processes.

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Oliveira, Filipa M., Teresa G. Nunes, Nadya V. Dencheva, and Zlatan Z. Denchev. "Structure and Molecular Dynamics in Metal-Containing Polyamide 6 Microparticles." Crystals 12, no. 11 (November 5, 2022): 1579. http://dx.doi.org/10.3390/cryst12111579.

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Polymer microparticles are used in additive manufacturing, separation and purification devices, biocatalysis, or for the recognition of biomolecules. This study reports on the effect of metal fillers on the structure and molecular dynamics of polyamide 6 (PA6) microparticles (MPs) containing up to 19 wt.% of Al, Cu, or Mg. These hybrid MPs are synthesized via reactive microencapsulation by anionic ring-opening polymerization in solution, in the presence of the metal filler. 13C high-resolution solid-state NMR (ssNMR) spectroscopy is employed as the primary characterization method using magic angle spinning (MAS) and cross-polarization (CP)/MAS. Depending on the metal filler, the ssNMR crystallinity index of the MP varies between 39–50%, as determined by deconvolution of the 13C MAS and CP/MAS spectra. These values correlate very well with the crystallinity derived from thermal or X-ray diffraction data. The molecular dynamics study on PA6 and Cu-containing MP shows similar mobility of carbon nuclei in the kHz, but not in the MHz frequency ranges. The paramagnetic Al and Mg have an observable effect on the relaxation; however, conclusions regarding the PA6 carbon motions cannot be unequivocally made. These results are useful in the preparation of hybrid microparticles with customized structures and magneto-electrical properties.

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Rosenthal, Stephan, Fabian Maaß, Mike Kamaliev, Marlon Hahn, Soeren Gies, and A. Erman Tekkaya. "Lightweight in Automotive Components by Forming Technology." Automotive Innovation 3, no. 3 (July 31, 2020): 195–209. http://dx.doi.org/10.1007/s42154-020-00103-3.

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AbstractLightweight design is one of the current key drivers to reduce the energy consumption of vehicles. Design methodologies for lightweight components, strategies utilizing materials with favorable specific properties and hybrid materials are used to increase the performance of parts for automotive applications. In this paper, various forming processes to produce light parts are described. Material lightweight design is discussed, covering the manufacturing processes to produce hybrid components like fiber–metal, polymer–metal and metal–metal composites, which can be used in subsequent deep drawing or combined forming processes. Approaches to increasing the specific strength and stiffness with thermomechanical forming processes as well as the in situ control of the microstructure of such components are presented. Structure lightweight design discusses possibilities to plastically form high-strength or high-performance materials like magnesium or titanium in sheet, profile and tube forming operations. To join those materials and/or dissimilar materials, new joining by forming technologies are shown. To economically produce lightweight parts with gears or functional elements, incremental sheet-bulk metal forming is presented. As an important part property, the damage evolution during the forming operations will be discussed to enable even lighter parts through a more reliable design. New methods for predicting and tailoring the mechanical properties like strength and residual stresses will be shown. The possibilities of system lightweight design with forming technologies are presented. A combination of additive manufacturing and forming to produce highly complex parts with integrated functions will be shown. The integration of functions by a hot extrusion process for the manufacturing of shape memory alloys is presented. An in-depth understanding of the newly developed processes, methodologies and effects allows for a more accurate dimensioning of components. This facilitates a reduction in the total mass and an increasing performance of vehicle components.

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Martins, Guilherme, Carlos M. S. Vicente, and Marco Leite. "Polymer-Metal Adhesion of Single-Lap Joints Using Fused Filament Fabrication Process: Aluminium with Carbon Fiber Reinforced Polyamide." Applied Sciences 13, no. 7 (March 30, 2023): 4429. http://dx.doi.org/10.3390/app13074429.

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Additive manufacturing (AM) is often used for prototyping; however, in recent years, there have been several final product applications, namely the development of polymer-metal hybrid (PMH) components that have emerged. In this paper, the objective is to characterize the adhesion of single-lap joints between two different materials: aluminium and a polymer-based material manufactured by fused filament fabrication (FFF). Single-lap joints were fabricated using an aluminium substrate with different surface treatments: sandpaper polishing (SP) and grit blasting (GB). Three filaments for FFF were tested: acrylonitrile butadiene styrene (ABS), polyamide (PA), and polyamide reinforced with short carbon fibers (PA + CF). To characterize the behaviour of these single-lap joints, mechanical tension loading tests were performed. The analysis of the fractured surface of the joints aimed to correlate the adhesion performance of each joint with the occurred failure mode. The obtained results show the impact of surface roughness (0.16 < Ra < 1.65 µm) on the mechanical properties of the PMH joint. The ultimate lap shear strength (ULSS) of PMH single-lap joints produced by FFF (1 < ULSS < 6.6 MPa) agree with the reported values in the literature and increases for substrates with a higher surface roughness, remelting of the primer (PA and PA + CF), and higher stiffness of the polymer-based adherent.

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Chakravarthy, Chitra, Daisy Aranha, Santosh Kumar Malyala, and Ravi S. Patil. "Cast Metal Surgical Guides: An Affordable Adjunct to Oral and Maxillofacial Surgery." Craniomaxillofacial Trauma & Reconstruction Open 5 (January 1, 2020): 247275122096026. http://dx.doi.org/10.1177/2472751220960268.

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Additive manufacturing or 3-dimensional (3D) printing technology has an incredulous ability to create complex constructs with high exactitude. Surgical guides printed using this technology allows the transfer of the virtual surgical plan to the operating table, optimizing aesthetic outcomes, and functional rehabilitation. A vast variety of materials are currently being used in medical 3D printing, including metals, ceramics, polymers, and composites. The guides fabricated with titanium have high strength, excellent biocompatibility, and are sterilizable but take time to print and are expensive. We have thus followed a hybrid approach to fabricate an inexpensive surgical guide using metal where the advantage of 3D printing technology has been combined with the routinely followed investment casting procedure to fabricate guides using nickel–chromium, which has all the advantages of a metal and is cost-effective.

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Verma, Ayush, Angshuman Kapil, Damjan Klobčar, and Abhay Sharma. "A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure." Materials 16, no. 15 (July 26, 2023): 5246. http://dx.doi.org/10.3390/ma16155246.

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Additive manufacturing (AM) has experienced exponential growth over the past two decades and now stands on the cusp of a transformative paradigm shift into the realm of multi-functional component manufacturing, known as multi-material AM (MMAM). While progress in MMAM has been more gradual compared to single-material AM, significant strides have been made in exploring the scientific and technological possibilities of this emerging field. Researchers have conducted feasibility studies and investigated various processes for multi-material deposition, encompassing polymeric, metallic, and bio-materials. To facilitate further advancements, this review paper addresses the pressing need for a consolidated document on MMAM that can serve as a comprehensive guide to the state of the art. Previous reviews have tended to focus on specific processes or materials, overlooking the overall picture of MMAM. Thus, this pioneering review endeavors to synthesize the collective knowledge and provide a holistic understanding of the multiplicity of materials and multiscale processes employed in MMAM. The review commences with an analysis of the implications of multiplicity, delving into its advantages, applications, challenges, and issues. Subsequently, it offers a detailed examination of MMAM with respect to processes, materials, capabilities, scales, and structural aspects. Seven standard AM processes and hybrid AM processes are thoroughly scrutinized in the context of their adaptation for MMAM, accompanied by specific examples, merits, and demerits. The scope of the review encompasses material combinations in polymers, composites, metals-ceramics, metal alloys, and biomaterials. Furthermore, it explores MMAM’s capabilities in fabricating bi-metallic structures and functionally/compositionally graded materials, providing insights into various scale and structural aspects. The review culminates by outlining future research directions in MMAM and offering an overall outlook on the vast potential of multiplicity in this field. By presenting a comprehensive and integrated perspective, this paper aims to catalyze further breakthroughs in MMAM, thus propelling the next generation of multi-functional component manufacturing to new heights by capitalizing on the unprecedented possibilities of MMAM.

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Pragana, João P. M., Stephan Rosenthal, Ivo M. F. Bragança, Carlos M. A. Silva, A. Erman Tekkaya, and Paulo A. F. Martins. "Hybrid Additive Manufacturing of Collector Coins." Journal of Manufacturing and Materials Processing 4, no. 4 (December 9, 2020): 115. http://dx.doi.org/10.3390/jmmp4040115.

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The objective of this paper is to present a new hybrid additive manufacturing route for fabricating collector coins with complex, intricate contoured holes. The new manufacturing route combines metal deposition by additive manufacturing with metal cutting and forming, and its application is illustrated with an example consisting of a prototype coin made from stainless steel AISI 316L. Experimentation and finite element analysis of the coin minting operation with the in-house computer program i-form show that the blanks produced by additive manufacturing and metal cutting can withstand the high compressive pressures that are attained during the embossing and impressing of lettering and other reliefs on the coin surfaces. The presentation allows concluding that hybrid additive manufacturing opens the way to the production of innovative collector coins with geometric features that are radically different from those that are currently available in the market.

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Mak, Sze Yi, Kwong Leong Tam, Ching Hang Bob Yung, and Wing Fung Edmond Yau. "Hybrid Metal 3D Printing for Selective Polished Surface." Materials Science Forum 1027 (April 2021): 136–40. http://dx.doi.org/10.4028/www.scientific.net/msf.1027.136.

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Metal additive manufacturing has found broad applications in diverse disciplines. Post processing to homogenize and improve surface finishing remains a critical challenge to additive manufacturing. We propose a novel one-stop solution of adopting hybrid metal 3D printing to streamlining the additive manufacturing workflow as well as to improve surface roughness quality of selective interior surface of the printed parts. This work has great potential in medical and aerospace industries where complicated and high-precision additive manufacturing is anticipated.

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Balyakin, A. V., M. A. Oleynik, E. P. Zlobin, and D. L. Skuratov. "A review of hybrid additive manufacturing of metal parts." VESTNIK of Samara University. Aerospace and Mechanical Engineering 21, no. 2 (July 7, 2022): 48–64. http://dx.doi.org/10.18287/2541-7533-2022-21-2-48-64.

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This article provides an overview of the latest developments in the field of hybrid additive manufacturing of metal parts. The concept and various kinds of additive manufacturing are discussed. Special attention is paid to hybridization of additive technologies and various processes of forming: die forging, deep drawing, and others. The background and significance of the technologies, as well as their applicability in production are presented. The combination of additive manufacturing with forming processes is carried out with a dual purpose: to expand the area of application of additive manufacturing and overcome its limitations associated with low productivity, metallurgical defects, surface roughness and lack of dimensional accuracy; new application of traditional forming processes.

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Pawlowski, Alexander E., Derek A. Splitter, Thomas R. Muth, Amit Shyam, J. Keith Carver, Ralph B. Dinwiddie, Amelia M. Elliott, Zachary C. Cordero, and Matthew R. French. "Producing Hybrid Composites By Combining Additive Manufacturing and Casting." AM&P Technical Articles 175, no. 7 (October 1, 2017): 16–21. http://dx.doi.org/10.31399/asm.amp.2017-07.p016.

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Abstract Additive manufacturing by itself provides many benefits, but by combining different materials processing techniques like traditional casting with additive manufacturing to create hybrid processes, custom materials can be tailor-made and mass produced for applications with specific performance needs. This article reports on research to create metal-metal interpenetrating phase composite materials using additive manufacturing and casting methods in combination.

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Di Caprio, Francesco, Valerio Acanfora, Stefania Franchitti, Andrea Sellitto, and Aniello Riccio. "Hybrid Metal/Composite Lattice Structures: Design for Additive Manufacturing." Aerospace 6, no. 6 (June 16, 2019): 71. http://dx.doi.org/10.3390/aerospace6060071.

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This paper introduces a numerical tool developed for the design and optimization of axial-symmetrical hybrid composite/metal structures. It is assumed that the defined structures are produced by means of two different processes: Additive Layer Manufacturing (ALM) for the metallic parts and Filament Winding (FW) for the composite parts. The defined optimization procedure involves two specific software: ANSYS and ModeFrontier. The former is dedicated to the production of the geometrical and FE models, to the structural analysis, and to the post-process, focusing on the definition of the Unit Cells for the modelling of the metal part. The latter is dedicated to the definition of the best design set and thus to the optimization flow management. The core of the developed numerical procedure is the routine based on the Ansys Parametric Design Language (APDL), which allows an automatic generation of any geometrical model defined by a generic design set. The developed procedure is able to choose the best design, in terms of structural performance, changing the lattice metallic parameters (number of unit cells and their topology) and the composite parameters (number of plies and their orientation). The introduced numerical tool has been used to design several hybrid structures configurations. These configurations have been analysed in terms of mechanical behaviour under specific boundary conditions and compared to similar conventional metal structure.

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Escher, C., and C. Mutke. "Additive Manufacturing of Tool Steels*." HTM Journal of Heat Treatment and Materials 77, no. 2 (April 1, 2022): 143–55. http://dx.doi.org/10.1515/htm-2022-1002.

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Abstract Additive manufacturing of tool steels represents a great challenge, yet it offers new possibilities for the tool manufacture of, for example, complex forming tools with conformal cooling. First, this contribution gives an overview of the most relevant additive manufacturing processes, the materials and processing concepts. By means of a hybrid manufactured press hardening tool for high-strength sheet metal parts, an example of practical implementation is presented subsequently.

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Pragana, J. P. M., R. F. V. Sampaio, I. M. F. Bragança, C. M. A. Silva, and P. A. F. Martins. "Hybrid metal additive manufacturing: A state–of–the-art review." Advances in Industrial and Manufacturing Engineering 2 (May 2021): 100032. http://dx.doi.org/10.1016/j.aime.2021.100032.

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Królikowski, Marcin A., and Marta B. Krawczyk. "Metal cutting and additive manufacturing as an integral stages of metals hybrid manufacturing in Industry 4.0." Mechanik 91, no. 8-9 (September 10, 2018): 769–71. http://dx.doi.org/10.17814/mechanik.2018.8-9.129.

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This paper describes the role of metal cutting process as integral part of manufacturing with application of MAM (metal additive manufacturing) techniques. Additive manufacturing is written explicit as main feature included in Industry 4.0 cycle. AM techniques lead to hybrid manufacturing techniques as well. This paper points that AM almost always is accompanied by supplementary conventional machining.

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Hinton, Jack, Dejan Basu, Maria Mirgkizoudi, David Flynn, Russell Harris, and Robert Kay. "Hybrid additive manufacturing of precision engineered ceramic components." Rapid Prototyping Journal 25, no. 6 (July 8, 2019): 1061–68. http://dx.doi.org/10.1108/rpj-01-2019-0025.

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Purpose The purpose of this paper is to develop a hybrid additive/subtractive manufacturing platform for the production of high density ceramic components. Design/methodology/approach Fabrication of near-net shape components is achieved using 96 per cent Al3O2 ceramic paste extrusion and a planarizing machining operations. Sacrificial polymer support can be used to aid the creation of overhanging or internal features. Post-processing using a variety of machining operations improves tolerances and fidelity between the component and CAD model while reducing defects. Findings This resultant three-dimensional monolithic ceramic components demonstrated post sintering tolerances of ±100 µm, surface roughness’s of ∼1 µm Ra, densities in excess of 99.7 per cent and three-point bending strength of 221 MPa. Originality/value This method represents a novel approach for the digital fabrication of ceramic components, which provides improved manufacturing tolerances, part quality and capability over existing additive manufacturing approaches.

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Stavropoulos, Panagiotis, Harry Bikas, Oliver Avram, Anna Valente, and George Chryssolouris. "Hybrid subtractive–additive manufacturing processes for high value-added metal components." International Journal of Advanced Manufacturing Technology 111, no. 3-4 (October 2, 2020): 645–55. http://dx.doi.org/10.1007/s00170-020-06099-8.

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Abstract Hybrid process chains lack structured decision-making tools to support advanced manufacturing strategies, consisting of a simulation-enhanced sequencing and planning of additive and subtractive processes. The paper sets out a method aiming at identifying an optimal process window for additive manufacturing, while considering its integration with conventional technologies, starting from part inspection as a built-in functionality, quantifying geometrical and dimensional part deviations, and triggering an effective hybrid process recipe. The method is demonstrated on a hybrid manufacturing scenario, by dynamically sequencing laser deposition (DLM) and subtraction (milling), triggered by intermediate inspection steps to ensure consistent growth of a part.

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Strong, Danielle, Issariya Sirichakwal, Guha P. Manogharan, and Thomas Wakefield. "Current state and potential of additive – hybrid manufacturing for metal parts." Rapid Prototyping Journal 23, no. 3 (April 18, 2017): 577–88. http://dx.doi.org/10.1108/rpj-04-2016-0065.

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Purpose This paper aims to investigate the extent to which traditional manufacturers are equipped and interested in participating in a hybrid manufacturing system which integrates traditional processes such as machining and grinding with additive manufacturing (AM) processes. Design/methodology/approach A survey was conducted among traditional metal manufacturers to collect data and evaluate the ability of these manufacturers to provide hybrid – AM post-processing services in addition to their standard product offering (e.g. mass production). Findings The original equipment manufacturers (OEMs) surveyed have machine availability and an interest in adopting hybrid manufacturing to additionally offer post-processing services. Low volume parts which would be suitable for hybrid manufacturing are generally more profitable. Access to metal AM, process engineering time, tooling requirements and the need for quality control tools were equally identified as the major challenges for OEM participation in this evolving supply chain. Practical implications OEMs can use this research to determine if hybrid manufacturing is a possible fit for their industry using existing machine tools. Originality/value Survey data offer an unique insight into the readiness of metal manufacturers who play an integral role in the evolving hybrid supply chain ecosystem required for post-processing of AM metal parts. This study also suggests that establishing metal AM centers around OEMs as a shared resource to produce near-net AM parts would be beneficial.

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Lutter-Günther, Max, Stephan Wagner, Christian Seidel, and Gunther Reinhart. "Economic and Ecological Evaluation of Hybrid Additive Manufacturing Technologies Based on the Combination of Laser Metal Deposition and CNC Machining." Applied Mechanics and Materials 805 (November 2015): 213–22. http://dx.doi.org/10.4028/www.scientific.net/amm.805.213.

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Hybrid additive manufacturing technologies combine selective material deposition with a conventional milling process in one machine, enabling the production of complex metal parts and reducing the need for part specific tools. The hybrid technology offers technological advantages compared to more established additive fabrication processes, such as powder bed fusion. Compared to powder bed based additive processes, which are currently in a prevailing positon regarding AM adaption, hybrid additive technologies enable increased build rates, enhanced build volumes and a reduction of machine changes. In the Laser Metal Deposition (LMD) process, metal powder is deposited through a nozzle and melted by a laser on the surface of the part. By integrating the LMD process into a machining center, good surface roughness and low tolerances can be realized by means of e. g. milling without reclamping. In comparison to powder bed based processes, cost and resource input have not been investigated in detail. In this study, hybrid additive manufacturing technologies are analyzed regarding cost and resource input. A cost model for hybrid additive processes is introduced that enables the analysis of the manufacturing cost structure for a given part. Furthermore, the resource inputs for the operation of a hybrid production machine are estimated.

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KACZMAR, JACEK W., ROMAN WROBLEWSKI, LESZEK NAKONIECZNY, and JACEK IWKO. "Manufacturing and properties of metal-polymer type hybrid elements." Polimery 53, no. 07/08 (July 2008): 519–25. http://dx.doi.org/10.14314/polimery.2008.519.

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Altan, M., and B. Yavuz. "A Novel Method for Manufacturing Polymer/Metal Hybrid Structures." Acta Physica Polonica A 129, no. 4 (April 2016): 639–41. http://dx.doi.org/10.12693/aphyspola.129.639.

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Holzer, K., L. Maier, V. Böhm, and W. Volk. "Dimensional precision and wear of a new approach for prototype tooling in deep drawing." IOP Conference Series: Materials Science and Engineering 1284, no. 1 (June 1, 2023): 012078. http://dx.doi.org/10.1088/1757-899x/1284/1/012078.

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Abstract In this work, we present and evaluate a new approach for prototype tooling in deep drawing based on direct polymer additive tooling. With fused filament fabrication (FFF) a PLA shell is printed additively. Afterwards, this is filled with ultra-high performance concrete (UHPC). UHPC is characterized by its higher strength properties compared to conventional concrete materials, which makes the material feasible for forming applications. Two configurations of these hybrid UHPC polymer additive are possible: either the PLA shell is in contact with the sheet metal during forming or UHPC. The hybrid UHPC polymer additive tooling approach has the potential to be more cost-efficient for small series. The dimensional precision and wear of such hybrid tools is evaluated using a standard cup geometry. A test series of 30 cups with sheet metal DX56+Z with 1 mm thickness was drawn with the hybrid tools as well as with a polymeric tool and a conventional steel tool. The dimensional precision and wear of the prototype tools was evaluated optically.

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Manogharan, Guha, Richard Wysk, Ola Harrysson, and Ronald Aman. "AIMS – A Metal Additive-hybrid Manufacturing System: System Architecture and Attributes." Procedia Manufacturing 1 (2015): 273–86. http://dx.doi.org/10.1016/j.promfg.2015.09.021.

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Hafenecker, Jan, Dominic Bartels, Clara-Maria Kuball, Maximilian Kreß, Richard Rothfelder, Michael Schmidt, and Marion Merklein. "Hybrid process chains combining metal additive manufacturing and forming – A review." CIRP Journal of Manufacturing Science and Technology 46 (November 2023): 98–115. http://dx.doi.org/10.1016/j.cirpj.2023.08.002.

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Grzesik, Wit. "Hybrid manufacturing of metallic parts integrated additive and subtractive processes." Mechanik 91, no. 7 (July 9, 2018): 468–75. http://dx.doi.org/10.17814/mechanik.2018.7.58.

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This review paper highlights the hybrid manufacturing processes which integrate the additive and subtractive processes performing on one hybrid platform consisting of the LMD (laser metal deposition) unit and multi-axis CNC machining center. This hybrid technology is rapidly developed and has many applications in Production/Manufacturing 4.0 including the LRT (laser repair technology). In particular, some important rules and advantages as well as technological potentials of the integration of a powder metal deposition and finishing CNC milling/turning operations are discussed and overviewed. Some representative examples such as formation of difficult features around the part periphery, deposition of functional layers and coatings and repair of high-value parts in aerospace industry are provided. Moreover, the technological strategies, CAD/CAM and CAI programs and construction designs of the hybrid manufacturing platforms are explained. Some conclusions and future trends in the implementation of hybrid processes are outlined.

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Hehr, Adam, and Mark Norfolk. "A comprehensive review of ultrasonic additive manufacturing." Rapid Prototyping Journal 26, no. 3 (November 18, 2019): 445–58. http://dx.doi.org/10.1108/rpj-03-2019-0056.

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Purpose This paper aims to comprehensively review ultrasonic additive manufacturing (UAM) process history, technology advancements, application areas and research areas. UAM, a hybrid 3D metal printing technology, uses ultrasonic energy to produce metallurgical bonds between layers of metal foils near room temperature. No melting occurs in the process – it is a solid-state 3D metal printing technology. Design/methodology/approach The paper is formatted chronologically to help readers better distinguish advancements and changes in the UAM process through the years. Contributions and advancements are summarized by academic or research institution following this chronological format. Findings This paper summarizes key physics of the process, characterization methods, mechanical properties, past and active research areas, process limitations and application areas. Originality/value This paper reviews the UAM process for the first time.

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Belitz, Stefan, Tobias Todzy, Andrea Jäger, and Henning Zeidler. "Hybrid-additive Fertigung von Werkzeugkomponenten/Hybrid-Additive Manufacturing of Tool Components: Simulative Design of the Laser Metal Deposition Process." wt Werkstattstechnik online 110, no. 06 (2020): 418–23. http://dx.doi.org/10.37544/1436-4980-2020-06-58.

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Durch die wachsende Produktvielfalt nimmt das Potenzial der additiven Fertigung im Werkzeugbau stetig zu. Ein neuartiger Ansatz ist die hybrid-additive Herstellung von Werkzeugkomponenten mittels Laserauftragschweißen. Mithilfe numerischer Simulationen können effiziente Verfahrstrategien analysiert und prozessbedingte Eigenspannungen und Verformungen reduziert werden. Im Rahmen dieser Arbeit wird ein Finite-Elemente-Modell für den Laserauftragschweißprozess entwickelt und in der Software „LS-Dyna“ validiert.   Due to the rising variety of products, the potential of additive manufacturing in tool making is continuously increasing. A novel approach is the hybrid-additive manufacturing of tool components using laser metal deposition (LMD). Numerical simulations can be used to analyze efficient scanning strategies and reduce process-related residual stresses and deformations. Within the scope of this work, a finite-element-model for the LMD process is developed and validated within the software LS-Dyna.

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Nyamuchiwa, Kudakwashe, Robert Palad, Joan Panlican, Yuan Tian, and Clodualdo Aranas. "Recent Progress in Hybrid Additive Manufacturing of Metallic Materials." Applied Sciences 13, no. 14 (July 20, 2023): 8383. http://dx.doi.org/10.3390/app13148383.

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Additive Manufacturing (AM) is an advanced technology that has been primarily driven by the demand for production efficiency, minimized energy consumption, and reduced carbon footprints. This process involves layer-by-layer material deposition based on a Computer-Aided Design (CAD) model. Compared to traditional manufacturing methods, AM has enabled the development of complex and topologically functional geometries for various service parts in record time. However, there are limitations to mass production, the building rate, the build size, and the surface quality when using metal additive manufacturing. To overcome these limitations, the combination of additive manufacturing with traditional techniques such as milling and casting holds the potential to provide novel manufacturing solutions, enabling mass production, improved geometrical features, enhanced accuracy, and damage repair through net-shape construction. This amalgamation is commonly referred to as hybrid manufacturing or multi-material additive manufacturing. This review paper aimed to explore the processes and complexities in hybrid materials, joining techniques, with a focus on maraging steels. The discussion is based on existing literature and focuses on three distinct joining methods: direct joining, gradient path joining, and intermediate section joining. Additionally, current challenges for the development of the ideal heat treatment for hybrid metals are discussed, and future prospects of hybrid additive manufacturing are also covered.

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Rajendran, Sundarakannan, Geetha Palani, Arunprasath Kanakaraj, Vigneshwaran Shanmugam, Szymon Gądek, Kinga Korniejenko, and Uthayakumar Marimuthu. "Metal and Polymer Based Composites Manufactured Using Additive Manufacturing—A Brief Review." Polymers 15, no. 11 (June 2, 2023): 2564. http://dx.doi.org/10.3390/polym15112564.

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This review examines the mechanical performance of metal- and polymer-based composites fabricated using additive manufacturing (AM) techniques. Composite materials have significantly influenced various industries due to their exceptional reliability and effectiveness. As technology advances, new types of composite reinforcements, such as novel chemical-based and bio-based, and new fabrication techniques are utilized to develop high-performance composite materials. AM, a widely popular concept poised to shape the development of Industry 4.0, is also being utilized in the production of composite materials. Comparing AM-based manufacturing processes to traditional methods reveals significant variations in the performance of the resulting composites. The primary objective of this review is to offer a comprehensive understanding of metal- and polymer-based composites and their applications in diverse fields. Further on this review delves into the intricate details of metal- and polymer-based composites, shedding light on their mechanical performance and exploring the various industries and sectors where they find utility.

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Cunico, Marlon Wesley Machado, and Jonas de Carvalho. "Development of additive manufacturing technology based on selective metal-polymer composite formation." Rapid Prototyping Journal 24, no. 1 (January 2, 2018): 52–68. http://dx.doi.org/10.1108/rpj-12-2016-0200.

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Purpose During the past years, numerous market segments have increasingly adopted additive manufacturing technologies for product development and complex parts design. Consequently, recent developments have expanded the technologies, materials and applications in support of emerging needs, in addition to improving current processes. The present work aims to propose and characterise a new technology that is based on selective formation of metal-polymer composites with low power source. Design/methodology/approach To develop this project, the authors have divided this work in three parts: material development, process feasibility and process optimisation. For the polymeric material development, investigation of metallic and composite materials assessed each material’s suitability for selective composite formation besides residual material removal. The primary focus was the evaluation of proposed process feasibility. The authors applied multivariable methods, where the main responses were line width, penetration depth, residual material removal feasibility, layer adherence strength, mechanical strength and dimensional deviation of resultant object. The laser trace speed, distance between formation lines and laser diameter were the main variables. Removal agent and polymeric material formulation were constants. In the last part of this work, the authors applied a multi-objective optimisation. The optimisation objectives minimized processing time and dimensional deviation while maximizing mechanical strength in xy direction and mechanical strength in z direction. Findings With respect to material development, the polymeric material tensile strength was found between 30 and 45 MPa at break. It was also seen that this material has low viscosity before polymerized (between 2 and 20 cP) essential for composite formation and complete material removal. In that way, the authors also identified that the residual material removal process was possible by redox reaction. In contrast with that the final object was marked by the polymer which covers the metallic matrix, protecting the object protects against chemical reactions. For the feasibility study, the authors identified the process windows for adherence between composite layers, demonstrating the process feasibility. The composite mechanical strength was shown to be between 120 and 135 MPa in xy direction and between 35 and 45 MPa in z direction. In addition, the authors have also evidenced that the geometrical dimensional distortion might vary until 5 mm, depending on process configuration. Despite that, the authors identified an optimised configuration that exposes the potential application of this new technology. As this work is still in a preliminary development stage, further studies are needed to be done to better understand the process and market segments wherein it might be applied. Originality/value This paper proposed a new and innovative additive manufacturing technology which is based on metal-polymer composites using low power source. Additionally, this work also described studies related to the investigation of concept feasibility and proposed process characterisation. The authors have focused on material development and studied the functional feasibility, which at the same time might be useful to the development of other additive manufacturing processes.

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Strong, Danielle, Michael Kay, Thomas Wakefield, Issariya Sirichakwal, Brett Conner, and Guha Manogharan. "Rethinking reverse logistics: role of additive manufacturing technology in metal remanufacturing." Journal of Manufacturing Technology Management 31, no. 1 (August 7, 2019): 124–44. http://dx.doi.org/10.1108/jmtm-04-2018-0119.

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Purpose Although the adoption of metal additive manufacturing (AM) for production has continuously grown, in-house access to production grade metal AM systems for small and medium enterprises (SMEs) is a major challenge due to costs of acquiring metal AM systems, specifically powder bed fusion AM. On the other hand, AM technology in directed energy deposition (DED) has been evolving in both: processing capabilities and adaptable configuration for integration within existing traditional machines that are available in most SME manufacturing facilities, e.g. computer numerical control (CNC) machining centers. Integrating DED with conventional processes such as machining and grinding into Hybrid AM is well suited for remanufacturing of metal parts. The paper aims to discuss these issues. Design/methodology/approach Classical facility location models are employed to understand the effects of SMEs adopting DED systems to offer remanufacturing services. This study identifies strategically located counties in the USA to advance hybrid AM for reverse logistics using North American Industry Classification System (NAICS) data on geographical data, demand, fixed and transportation costs. A case study is also implemented to explore its implications on remanufacturing of high-value parts on the reverse logistics supply chain using an aerospace part and NAICS data on aircraft maintenance, repair and overhaul facilities. Findings The results identify the candidate counties, their allocations, allocated demand and total costs. Offering AM remanufacturing services to traditional manufacturers decreases costs for SMEs in the supply chain by minimizing expensive new part replacement. The hubs also benefit from hybrid AM to repair their own parts and tools. Originality/value This research provides a unique analysis on reverse logistics through hybrid AM focused on remanufacturing rather than manufacturing. Facility location using real data is used to obtain results and offers insights into integrating AM for often overlooked aspect of remanufacturing. The study shows that SMEs can participate in the evolving AM economy through remanufacturing services using significantly lower investment costs.

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Vakharia, Ved S., Lily Kuentz, Anton Salem, Michael C. Halbig, Jonathan A. Salem, and Mrityunjay Singh. "Additive Manufacturing and Characterization of Metal Particulate Reinforced Polylactic Acid (PLA) Polymer Composites." Polymers 13, no. 20 (October 14, 2021): 3545. http://dx.doi.org/10.3390/polym13203545.

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Affordable commercial desktop 3-D printers and filaments have introduced additive manufacturing to all disciplines of science and engineering. With rapid innovations in 3-D printing technology and new filament materials, material vendors are offering specialty multifunctional metal-reinforced polymers with unique properties. Studies are necessary to understand the effects of filament composition, metal reinforcements, and print parameters on microstructure and mechanical behavior. In this study, densities, metal vol%, metal cross-sectional area %, and microstructure of various metal-reinforced Polylactic Acid (PLA) filaments were characterized by multiple methods. Comparisons are made between polymer microstructures before and after printing, and the effect of printing on the metal-polymer interface adhesion has been demonstrated. Tensile response and fracture toughness as a function of metal vol% and print height was determined. Tensile and fracture toughness tests show that PLA filaments containing approximately 36 vol% of bronze or copper particles significantly reduce mechanical properties. The mechanical response of PLA with 12 and 18 vol% of magnetic iron and stainless steel particles, respectively, is similar to that of pure PLA with a slight decrease in ultimate tensile strength and fracture toughness. These results show the potential for tailoring the concentration of metal reinforcements to provide multi-functionality without sacrificing mechanical properties.

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Abel, Arvid, Vurgun Sayilgan, Robert Bernhard, Jörg Hermsdorf, Stefan Kaierle, and Ludger Overmeyer. "Advances in powder bed based Additive Manufacturing of metal-glass-hybrid-components." Procedia CIRP 111 (2022): 111–14. http://dx.doi.org/10.1016/j.procir.2022.08.066.

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GRZESIK, Wit. "HYBRID ADDITIVE AND SUBTRACTIVE MANUFACTURING PROCESSES AND SYSTEMS: A REVIEW." Journal of Machine Engineering 18, no. 4 (November 30, 2018): 5–24. http://dx.doi.org/10.5604/01.3001.0012.7629.

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This review paper highlights the hybrid manufacturing processes which integrate the additive and subtractive processes performing on one hybrid platform consisting of the LMD (laser metal deposition) unit and CNC machine tools. In particular, some important rules and advantages as well as technological potentials of the integration of different AM technique and finishing CNC machining operations are discussed and overviewed. Some representative examples such as formation of difficult features around the part periphery, deposition of functional layers and coatings and repair of high-value parts in aerospace industry are provided. Some conclusions and future trends in the implementation of hybrid processes are outlined.

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Gackowski, Bartosz Mikolaj, Helixman Phua, Mohit Sharma, and Sridhar Idapalapati. "Hybrid additive manufacturing of polymer composites reinforced with buckypapers and short carbon fibres." Composites Part A: Applied Science and Manufacturing 154 (March 2022): 106794. http://dx.doi.org/10.1016/j.compositesa.2021.106794.

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Journal articles on the topic 'Hybrid Metal and Polymer Additive Manufacturing'

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