Multi-Station Multi-Axis Hybrid Layered Manufacturing (MSMA-HLM)

Additive manufacturing is advanced manufacturing technology in which material is added layer by layer. The hybrid approach with conventional and additive processes is utilized for making the component faster and cost-effective. Hybrid Layered Manufacturing (HLM) is the process in which a 3D component is made by adding and subtracting material layer by layer. HLM is basically for a metallic component in which material is added by depositing metal in wire form through an arc, LASER, EBM, and a small amount of material is removed by machining and thus making the system hybrid. There are various levels of hybridization in terms of approach, material, layering, joining process, kinematics and operations. A complete setup of HLM is developed with multiple stations and with a simultaneous five-axis system named as Multi-Station Multi-Axis Hybrid layered Manufacturing (MSMA-HLM). MSMA-HLM has its application in aerospace, automobile, marine, medical, etc. The various case studies with the HLM process are also demonstrated in this paper with cost and time compared with conventional manufacturing. The need for multiple stations during the HLM process is explained in this paper. The preheating, hammering, and inspection units are the add-ons in the manufacturing process for making defect-free components. (c) 2022 Society of Manufacturing Engineers (SME). Published by Elsevier Ltd. All rights reserved.