They will enable injection molding that runs 40–50% faster than traditional straight line cooling with a 30–50% improvement in tool life while reducing cycle times. When the final parts come out, they are very nearly finished with complex designs including deep ribs and pockets and the complex geometry for conformal cooling channels. CAD modeling can create conformal cooling through simulation of thermal modeling and weight reduction can be achieved. “With our hybrid AM, the moldmaker can make components 24/7 untended. Conformal cooling channels enable injection molding that runs 40-50% faster than traditional straight line cooling with a 30-50% improvement in tool life while reducing cycle times. The potential across multiple components on each mold-24 parts across 24 molds-is significant,” said Houle. “A customer I worked with recently-a project tool maker-saved $5.5 million for the end customer over three years on one part of a 24-part component in the mold for that project. Hybrid AM is already a game-changer for the moldmaking industry with impressive potential,” said Houle. “We have to work with them to identify how the part or component of a mold, for example, can be improved by hybrid additive/subtractive technology.” Matsuura’s two hybrid powder bed machines, the Avance 25 and Avance 60, use Matsuura high-speed vertical machining center platforms to build and finish machine parts. “Growth for hybrid AM in moldmaking is limited only by the ability of customers to think beyond designing parts in terms of conventional machining,” said Tom Houle, director of Lumex North America, Matsuura Machinery USA Inc. (For a complete discussion of the technical underpinnings of hybrid AM technology as well as a trip through its arcane alphabet world, see “The Pluses and Minuses of Combining Additive & Subtractive Machining,” Manufacturing Engineering, July 2017). DED-based hybrid machines are excellent choices for larger metal parts and repair of critical aerospace, medical, and oil field workpieces.
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PBF-based hybrid machines are well suited to manufacturing molds with fewer components and process conformal heating/cooling channels and smaller, complex parts that formerly could not be produced. Akin in many respects to laser welding, both DED and PBF approaches are carving out roles for AM technology, working within a well-defined scope of work. This has been made possible through adaptation of the two principal delivery approaches, directed energy deposition (DED) and powder bed fusion (PBF) technology.
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You might call hybrid machines “Multitasking Plus.”ĪM, which began making plastic parts more than 30 years ago, has seen working envelopes grow and the addition of metal parts. And they are answering the challenge with a growing list of machines that marry additive manufacturing (AM) processes with proven, well-established subtractive machining platforms to produce parts complete on one machine. With their recent offerings, major machine tool builders are signaling that hybrid technology is more than an innovative extension of their manufacturing capabilities. DMG Mori’s Lasertec 3D hybrid combines five-axis machining with laser deposition welding with a powder nozzle.
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Hybrid is showing that there’s more than one way to reduce cycle times and boost the bottom line as long as the total cost of manufacturing processes is considered. Still in its early development stages, hybrid machine technology is carving out-after carefully building up layer by layer-examples of complex parts, large repaired workpieces, and molds with process-enhancing conformal cooling channels designed in.
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There will be a lot of success stories coming out soon featuring hybrid additive/subtractive machine technology.