Hybrid metal manufacturing of large freeform geometries

Abstract

An integrated, multi-system research platform has been developed to explore the fabrication of large-scale metal components though hybrid manufacturing. The resulting research cell is highly flexible as it incorporates multiple robot stations, a multi-axis part transfer system and a five-axis CNC machine tool. Current process capabilities include multi-material wire-arc additive manufacturing, fringe projection scanning metrology, robotic part handling and finish machining. A geometric digital twin is used to establish and transfer part positions, datums and coordinate axes across these processes. Mechanical and electrical system integration is complete and a sequential process flow has been demonstrated by fabricating a monolithic, single wall part geometry.