Analyses of the Product Development Process for Multi-Material Products Combining Additive and Subtractive Manufacturing Technologies

In a long-term perspective, this project targets the development of the additive manufacturing technology Fused Layer Modelling (FLM) for the industrial application in production processes. The five involved research facilities design a production system for the integration of additive and subtractive production technologies. Thus, the complete Product Development Process (PDP) as well as the qualification and combination of innovative materials are in focus. The technological interfaces of the FLM process are analyzed and an extension of the production potential by intermediate- or post-processing like surface treatment or machining are evaluated.

The work package of the ISF includes the experimental and simulation-based analysis of the machining technology within the PDP chain. The temperature and layer thickness of a FLM generated workpiece are key interfaced when additive and subtractive processes are serially combined. Thus, the institute of product engineering (RTC) at the University of Duisburg-Essen generates test workpieces with certain layer thicknesses, which will be machined at the ISF using a variation of specific process parameters and different tool geometries. The command variables are constituted by the average surface roughness RZ as well as the geometrical deviation and tensile strength. Based on these results, empirical models for the process simulation and optimization of process parameters and tool geometries are defined and parametrized. Thereby optimal and reliable process parameter values and tool geometries, as well as technological boundaries for specific FLM process conditions and materials are determined. This information constitutes determining factors for the NC-path planning and process control.

Fig.: Exemplary application for above-knee protheses