Hybrid rapid manufacturing of metallic objects

While CNC machining, the subtractive method, is the only option when it comes to high quality components, the need for human intervention to generate the CNC programs makes it a slow and costly route. On the other hand, rapid prototyping (RP), the additive method, is able to convert the design into the physical objects without any human intervention but its total automation comes with compromises in the qualities of geometry and material. A balance between these two extremes is hybrid rapid manufacturing (HRM). In HRM, the near-net shape of the component is built in layers (additive method) and the same is finish-machined (subtractive method). While the priority during material addition is material integrity, the same is on geometric quality during material subtraction. As the focuses in both these steps are different, they are very fast. The existing HRM processes for metallic objects are reviewed in this paper followed by a brief description of ArcHLM under development at IIT Bombay. The generic ArcHLM facility or Hybrid FMS will be able to demonstrate its various applications of for fresh manufacture and repair of tools and components