Synergy Strategies between Additive Manufacturing and Machining for High Value Added Components

Additive manufacturing (AM) enables freedom of design, part complexity with minimal added cost, light weighting, design for function, and part consolidation. AM, in general, is considered to have great potentials in complementing conventional manufacturing methods. Functional parts with high strength to weight radio generated using topology optimization can be eventually realised by AM. Limitations of AM parts related to surface finish and dimensional accuracy are likely to be eliminated by post machining of critical features and surfaces in order to achieve specific tolerance and surface quality. As a result, AM and machining simulations are essential for effective planning of the synergized processes. The goal of this study is to propose a process workflow that synergizes AM, particularly laser powder bed fusion (LPBF), and CNC machining. The workflow is deployed and iterated through a case study of manufacturing a surgical tool using AM followed by post machining. The holistic manufacturing process involves CAD design utilizing topology optimization, AM simulation, machining simulation, fabrication, and validation.