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2024-08-19 17:46:26

The ADIVAT project (Transfer of Latest Generation Additive Manufacturing Technologies for Prototyping High Added Value Components for the Transport Sector), focuses on the transfer of knowledge in additive manufacturing technologies applied to the development of...

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Another remarkable advantage is that hybrid manufacturing eliminates much of the waste that is inherent to subtractive technologies, reducing material consumption by up to 97%, one recent study found. 3D printing the part to a near-net shape means less material ends up as shavings on the factory floor. With DED/CNC machines, it’s also possible to add material only to select locations.

Automotive: Vehicle engines and chassis contain huge numbers of complex parts. Hybrid manufacturing gives automotive manufacturers to produce these components in a single machine, lowering material and labor costs.

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The Meltio system is a Directed Energy Deposition (DED) process that precisely stacks weld beads on top of one another in wire form when introduced into the laser-generated melt pool. Meltio’s technology comes packaged in a compact deposition head with six low-power lasers that are capable of processing metal welding wire fed coaxially. The head is mounted next to the CNC milling machine spindle mount.

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Another important fact is that hybrid manufacturing can achieve higher precision and tighter tolerances than most 3D printers alone. AM creates more complex geometries and part structures than machining can produce, such as part consolidation, internal channels, and lattice-filled walls. Producing the entire part in one machine also reduces the chance of processing flaws or errors. As a result, hybrid parts can perform better and have higher quality.

These machines can allow them to produce both kinds (or hybrid) parts without investing in two machines. It can also resolve (and has resolved) issues related to part complexity and productivity in demanding, large-scale industries, such as automotive and aerospace.

Medical: Hybrid manufacturing can help medical professionals create perfectly fitting customized implants, prosthetics, and surgical tools. The AM component allows for part customization, while CNC machining ensures an ideal part quality.

Ideally, a hybrid manufacturing machine should work with a single round of programming, and most manufacturers aim for simple operability. Some companies produce their own CAD/CAM solutions, although many rely on operating software developed by third parties.

This allows users to repair broken components and speed up production by adding metal to parts such as components used in the marine and oil & gas industries. Conversely, the CNC unit can machine fine internal structures between material deposition runs.

A growing number of hybrid manufacturing machines wrap 3D printing and CNC machinery into one package to better automate and accelerate part production.

3D printing and machining are often considered competitors, but they can also be effective partners. In fact, 3D printed parts are routinely machined to create higher tolerances and better surface finish. Meanwhile, parts that were once milled from a solid block of metal are often 3D printed far faster and in more complex shapes.

Despite its great advantages, hybrid isn’t a perfect solution for every manufacturing need. Although these machines can lower initial investment, they are not cheap and may be outside the budgets of smaller companies. Operating hybrid machines can be complicated and requires the operator to have an intricate understanding of both 3D printing and CNC machining to determine the best way to manufacture a given part.

Machine makers say hybrid technology overcomes the shortcomings of both of their parent technologies and enables manufacturers to produce more accurate and higher-quality components faster and at a lower cost. It is less wasteful than machining alone and more productive and precise than 3D printing alone, with no manual labor to move parts around an no programming two distinct pieces of equipment.

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Linares (Spain) June 5th, 2024.- Meltio - the leading manufacturer of industrial additive manufacturing wire-laser metal deposition systems - has announced today its firm commitment to expand its range of services and solutions in the United States (US). The growing...

In addition to building a part from scratch, these machines are ideal for adding features to existing parts, carrying out repairs of parts, and applying coatings to parts before the machining post process.

Sure-Form has decades of experience in the construction of large scale, reinforced concrete structures including water retaining structures. Sure-Form also has experience with lagoons, settling ponds, etc.

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Aerospace: The aerospace industry requires heat-resistant, strong, and lightweight parts with tight tolerances. Hybrid manufacturing can manufacture these components from reinforced thermoplastics and metals like aluminum.

Hybrid manufacturing is a working solution for producing both prototypes and functional end-use parts, in addition to repairing existing components. Hybrid manufacturing is particularly attractive to smaller companies that require both AM and machining capability.

Hybrid manufacturing is a relatively new method that combines additive manufacturing and subtractive manufacturing technology in one machine. These machines use 3D printing to produce the basic, near-net shape of the part in metal or plastic. Then, another unit or tool head mills the part to the required tolerances. As a result, manufacturers (and their customers) have the complex geometries of additive manufacturing and the detailed surface quality of milled components.

Hybrid manufacturing is suitable for a great number of industries. Any application that relies on precisely manufactured parts from metals or thermoplastic stands to benefit from hybrid manufacturing technologies. However, some of the sectors that are particularly suitable are these:

Last but not least, hybrid can cut up-front investment and running costs. Instead of purchasing both a CNC machine and an industrial 3D printer, it may be cheaper to buy a hybrid machine. A single hybrid machine also consumes less energy and requires less floor space than separate AM and CNC units.

Hybrid manufacturing offers many benefits over pure AM or subtractive methods. One of its most significant advantages is the ability to increase productivity. As both the AM and machining processes can be run in a single machine, there’s no need to swap parts and recalibrate equipment. The machining unit can also partially or completely replace manual AM post-processing, which also speeds up production.

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Linares (Spain), July 17th 2024. - The French Navy has validated the use of the unique additive manufacturing technology developed by Meltio for real maneuvers. The Spanish multinational has thus achieved the third approval of its metal 3D printing technology for the...

General Engineering: Maximum uptime is vital for any manufacturing industry. With hybrid manufacturing solutions, it’s possible to repair broken machinery components, which lowers costs and requires less standing inventory.

Sure-Form establishes a collaborative relationship with our clients. This approach prioritizes the project itself, with Project Management, Estimating, and Safety working closely with the Consultant and Client to develop project plans, safety plans, and schedules. This method commences at pre-construction and continues through the project to close out and warranty completion.

For example, Meltio offers Meltio Space, a state-of-the-art toolpath generator software for the Meltio Engine Robot Integration with an easy-to-use interface for planar, non-planar, and variable extrusion toolpaths for the ABB, Kuka, Fanuc, and Yaskawa robots.

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Hybrid machines enable you to use multiple materials in a single part, opening the door to significant mechanical performance improvements and cost savings. You can clad weaker parts in stronger metals, add high-performance materials to improve part movement or heat transfer, or save on material costs by using expensive materials only where they’re needed.

We will manage your project from start to finish with multiple scopes of work provided in-house, helping to expedite your project schedule.

SURE-FORM was founded in 1981 and over the course of 40+ years in operation has completed a diverse range of infrastructure construction projects.

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Spanish metal 3D printer maker, Meltio, offers a CNC integration unit called the Meltio Engine that can turn almost any industrial CNC machine or robotic platform into a hybrid metal manufacturing system with no inherent size constraints. By retrofitting your existing CNC machine, you’ll have a new capability to conduct cost-effective component creation, repair, part augmentation, and feature addition on metal parts, the company says.

Technically, almost any 3D printing technology could be combined with a CNC machine and there are a few upgrade kits to convert your existing machining units. However, the technology is still developing and the current options are limited to a few combinations. These include: