Freeform Hybrid Manufacturing: Binderjet, Structured Light Scanning, Confocal Microscopy, and CNC Machining

Dvorak, Jake; Gilmer, Dustin; Zameroski, Ross; Cornelius, Aaron; Schmitz, Tony

doi:10.3390/jmmp7020079

Freeform Hybrid Manufacturing: Binderjet, Structured Light Scanning, Confocal Microscopy, and CNC Machining

Journal Article · Tue Apr 18 00:00:00 EDT 2023 · Journal of Manufacturing and Materials Processing

DOI:https://doi.org/10.3390/jmmp7020079· OSTI ID:1970428

; Gilmer, Dustin; ; ;

This paper describes a hybrid manufacturing approach for silicon carbide (SiC) freeform surfaces using binder jet additive manufacturing (BJAM) to print the preform and machining to obtain the design geometry. Although additive manufacturing (AM) techniques such as BJAM allow for the fabrication of complex geometries, additional machining or grinding is often required to achieve the desired surface finish and shape. Hybrid manufacturing has been shown to provide an effective solution. However, hybrid manufacturing also has its own challenges, depending on the combination of processes. For example, when the subtractive and additive manufacturing steps are performed sequentially on separate systems, it is necessary to define a common coordinate system for part transfer. This can be difficult because AM preforms do not inherently contain features that can serve as datums. Additionally, it is important to confirm that the intended final geometry is contained within the AM preform. The approach described here addresses these challenges by using structured light scanning to create a stock model for machining. Results show that a freeform surface was machined with approximately 70 µm of maximum deviation from that which was planned.

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Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1970428

Journal Information:: Journal of Manufacturing and Materials Processing, Journal Name: Journal of Manufacturing and Materials Processing Journal Issue: 2 Vol. 7; ISSN JMMPBJ; ISSN 2504-4494

Publisher:: MDPI AGCopyright Statement

Country of Publication:: Switzerland

Language:: English

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