Hybrid rapid prototyping system using machining and deposition

Many rapid prototyping (RP) systems are commercially available, and others are introduced daily. RP has proven to be an effective tool for dramatically reducing the time and expense involved in the realization of a new products and for overcoming the bottlenecks of existing manufacturing processes. However, its ®elds of application are currently saturated, and the emphasis has moved towards using RP for short-run manufacture. The current need is for a technique that will produce ®nished parts of the required quality in the shortest possible time, and which meet this need, the focus now falls on improvements in production speed, accuracy, variety of materials, and cost. For these practical reasons, we concentrated on a new form of hybrid-RP system, which performs both deposition and machining in a single station. Our proposed system meets the requirements of material deposition (RP) and material removal (CNC) at the process planning and manufacturing level. We believe that this new production system, which incorporates a combined RP concept, offers an optimum manufacturing solution by adopting the advantages of the RP and CNC systems. In this paper, we describe the system architecture and the fabrication process in detail and present the framework of the process planning system and the concepts of the geometric algorithms involved in developing such an environment. q 2002 Elsevier Science Ltd. All rights reserved.