Purpose

This study presents a method for fabricating multi-material objects using a hybrid additive and subtractive approach. By hybridizing the material composition in addition to the fabrication process, functional requirements can be met more effectively than through homogenous material parts produced using a single manufacturing process. Development of multi-material objects consisting of dissimilar materials that have been hampered by a lack of a structural interface compatible with in-envelope hybrid additive and subtractive manufacturing.

Design/methodology/approach

This research presents a novel method for producing multi-material components through in-envelope hybrid additive and subtractive manufacturing. This study attempts to address the absence of a metal-polymer interface by integrating polymer additive manufacturing into a five-axis mill. The ability of the polymer additive system to reproduce overhang geometries is assessed with different levels of cooling. The relationship between structural performance, cooling and material flow rate is evaluated for the deposited carbon fiber reinforced acrylonitrile butadiene styrene.

Findings

A mechanically interlocking root structure is developed to form an interface between a machined aluminum region and a polymer region of an object. The tensile strength of the metal-polymer object is measured and found to be on the same order of magnitude as the bulk three-dimensional printed polymer.

Originality/value

By targeting the material properties to the local functional requirements within a part and taking advantage of both additive and subtractive manufacturing processes, this study will enable broader design options and optimization of performance metrics.

中文翻译：

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多材料物体的混合增材和减材制造

目的

本研究提出了一种使用混合加减法制造多材料物体的方法。通过在制造过程之外混合材料成分，与使用单一制造过程生产的均质材料部件相比，可以更有效地满足功能要求。由不同材料组成的多材料物体的开发由于缺乏与包络内混合增材和减材制造兼容的结构界面而受到阻碍。

设计/方法/方法

这项研究提出了一种通过包络内混合增材和减材制造生产多材料组件的新方法。本研究试图通过将聚合物增材制造集成到五轴铣床中来解决金属-聚合物界面的缺失问题。聚合物添加剂系统再现悬垂几何形状的能力通过不同程度的冷却进行评估。评估了沉积碳纤维增强丙烯腈丁二烯苯乙烯的结构性能、冷却和材料流速之间的关系。

发现

开发了一种机械互锁的根部结构，以在加工的铝区域和物体的聚合物区域之间形成界面。测量金属聚合物物体的拉伸强度，发现其与本体 3D 印刷聚合物处于同一数量级。

原创性/价值

通过将材料特性针对零件内的局部功能要求，并利用增材制造和减材制造工艺，这项研究将实现更广泛的设计选择和性能指标的优化。