Case studies will be presented for architectural, manufacturing tooling and industrial enclosure applications that illustrate the capabilities of a new process that combines large scale extrusion additive manufacturing, 5 axis CNC machining and in-situ high fidelity 3D scanning. The system features GRALE®, an ultra-precise metrology capability that can quickly capture dimensional measurements during the AM process for feedback control. GRALE® metrology also provides final exact geometry of the as-deposited structure providing information for CNC machining and post processing. The case studies will focus on the manufacturing quality assessment achieved during the production process, the complexity of design possible with 3D free space hybrid additive and the connections to an Industry 4.0 methodology through additional in process data collection and process monitoring. In-situ thermography captures processing temperatures for feedback control and thermal history to validate part integrity and microstructure against material models. Non-destructive testing (NDT) of the intra-layer diffusion for structural quality assessment is currently under selection.
- Identify product applications that may benefit from advanced designs possible with 3D free space hybrid additive manufacturing
- Qualitatively relate the benefits of schedule and level of quality assessment that is offered with in-situ high fidelity 3D scanning metrology during a hybrid additive manufacturing process
- Describe the impact that extensive multi-variable process monitoring will have towards product quality assessment and process validation with a fully instrumented hybrid AM system