The set-up of an integrated working concept factory using metal additive manufacturing

Abstract

In order to produce more complex parts, additive manufacturing is on the rise as a competitor for more conventional manufacturing methods. Unfortunately, additive manufacturing often produces products with a less desirable tolerance and surface roughness. Subtractive methods require special tooling and fixtures for each part design and typically produce parts with a better surface roughness and feature accuracy. This research focusses on the combination of both methods, in order to get a manufacturing process with a competitive advantage compared to conventional manufacturing methods and techniques.


The hypothesis of this thesis is that the combination of both additive and subtractive manufacturing can produce better results than both methods on its own. This can be done due to the production of near-net shaped parts with the additive manufacturing process and a better surface finish and accuracy due to the subtractive manufacturing process. In this research, The challenges and limitations of the combiation of both techniques are studied. This is done using the most well-known techniques used nowadays in industry, selective laser melting as additive manufacturing process and CNC machining as subtractive manufactuiring process, in order to make this research applicable in the real production evironment. Both the physical as digital integration of both techniques is researched, as well as the economic impact of the process on the manufacturing costs for low batch production of metal alloys.