A D D I T I V E M A N U F A C T U R I N G
ADDITIVE AND
SUBTRACTIVE IN ONE
DOES HYBRID MANUFACTURING OFFER THE BEST OF BOTH WORLDS?
In the wild, zebra and ostriches may appear to be unlikely allies. Here, EU Automation, explains how
sometimes a seemingly polarising combination can be very effective, particularly in the realm of additive
While zebra have excellent
eyesight and a poor sense of
smell, ostriches have weak
eyesight and a much better
sense of smell. By working together, they have a
greater chance at identifying threats and evading
predators. In much the same way, additive
and subtractive manufacturing may seem like
competitors, but by combining them, it is possible
to overcome their respective deficiencies.
The additive manufacturing market is growing
exponentially, and Asia-Pacific is expected to
be at the forefront of this multi-billion-dollar
market. Japan, China, Australia, and South
Korea are among the key global players, while
countries such as Singapore are seeing increased
government funding in this area.
Despite additive manufacturing being widely
heralded as revolutionary, it does have its own
set of drawbacks to contend with. Does hybrid
manufacturing offer a solution, and could it have
even greater potential than its predecessors?
Additive manufacturing, or 3D printing as it is
commonly referred to, denotes the production of
a part by adding, or “printing”, layers of a material
on top of one another. Additive manufacturing
results in less waste material, lighter and more
complex designs, and reduced lead times,
ideal for rapid prototyping. However, there are
drawbacks too; the printing process takes a long
time, and finished parts often have an uneven,
stepped surface.
Subtractive manufacturing, on the other hand,
means creating a product by gradually removing
material using techniques including drilling,
cutting, and grinding. This method is precise,
has a high productivity, and can achieve a range
of surface finishes. However, it results in a large
amount of waste material.
Hybrid manufacturing combines these two
methods. Additive and subtractive manufacturing
have been used within the same process for some
time, such as using CNC machining to smooth
the surface of a 3D-printed product. However,
the term hybrid manufacturing only applies when
MACHINE?
and subtractive machining.
these different techniques occur within the same
machine. These next generation machines may
look like a five-axis mill on first glance, but contain
a built-in cladding head to carry out additive
machining.
Therefore, hybrid manufacturing makes it possible
to alternate the two processes. A proportion of
a part can be printed, the internal surfaces and
features finished with subtractive tooling, followed
by the printing of the rest of the part. Additive
manufacturing’s limited accuracy and surface
finish are accounted with this combination of
methods, as milling is brought back into the
process after additive manufacturing, ensuring a
high-quality surface finish.
Another benefit is reducing waste by adding only
the amount of material necessary before tooling,
maximising the efficiency of any machining work
needed, and dramatically reducing costs. Hybrid
technologies can be used to build up and repair
damaged parts, or to combine different materials,
such as copper for heat transfer. While 3D printing
was once ubiquitous with polymers, hybrid
machines can use combine a range of metals
and alloys to create a single product, using more
costly materials only where required.
Hybrid CNC machines are expensive, but as only
one machine is needed for the full production
cycle, they could reduce overall capital equipment
costs in one compact footprint. They also
minimise the risk of error, as there is no need
to move a printed part to reset it on a separate
machine.
Applications of this technology are diverse, but
it is expected to make an impact on the medical,
automotive, electrical, aerospace, industrial
systems, and consumer goods sectors, amongst
others.
Just as the zebra and ostrich alliance is a
match, so too is the additive and subtractive
manufacturing combination. While it is yet to
reach its peak, new technologies and applications
are continually being discovered for hybrid
manufacturing. It will offer businesses in Asia-
Pacific the best of both worlds, enabling them
to make the most of the unrealised potential
promised by additive manufacturing.
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