Freeform Hybrid Manufacturing: Binderjet, Structured Light Scanning, Confocal Microscopy, and CNC Machining

This paper describes a hybrid manufacturing approach for silicon carbide (SiC) freeform surfaces using binder jet additive (BJAM) to print the preform and machining obtain design geometry. Although (AM) techniques such as BJAM allow fabrication of complex geometries, additional or grinding is often required achieve desired surface finish shape. Hybrid has been shown provide an effective solution. However, also its own challenges, depending on combination processes. For example, when subtractive steps are performed sequentially separate systems, it necessary define common coordinate system part transfer. can be difficult because AM preforms do not inherently contain features that serve datums. Additionally, important confirm intended final geometry contained within preform. The described here addresses these challenges by structured light scanning create stock model machining. Results show was machined with approximately 70 µm maximum deviation from which planned.