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Hybrid additive machine concept
Further testing In testing, the concept has proven it to be as capable as expected. The company are currently working on producing example test pieces and looking to move to the next stage with R&D projects of real-world products to trial manufacture, and funded R&D projects to investigate ways to manufacture new products that can’t be machined from billet. If you think you have a use case for this technology, then we would be happy to talk to you. The next step We are also looking to place the prototype machine in an R&D or manufacturing facility and find a machine tool OEM or partner to help develop the concept further and take this new and innovative machine design to market.
Using inverted workpiece and horizontal milling spindle configuration for efficient swarf clearing, the hybrid process allows near net shape metal deposition for minimal material removal and wastage, saving raw material and tooling costs. The design of the machine allows the design and manufacture of highly complex components to be printed and machined in multiple stages, to a finished product, machined in areas that can’t be reach by conventional methods from billet, on a single platform with no additional set ups. The advantage in using this approach means that new components can be designed around a completely flexible manufacturing process, with high deposition rates and minimal material removal. The design also facilitates repair operations on existing components such as casings and blisks, where material can be added, measured, machined and measured again on the same platform in a single set-up.
Effective CNC Solutions Ltd have developed and patented a new concept hybrid 5 axis Metal Additive Mill-Turn machine tool. Using a 3-axis bed mill format with a 2-axis trunnion table to manipulate the workpiece in 5-axis around fixed position spindle, turning turret and WAAM additive head stations. Controlled by the powerful Siemens - Sinumerik One - CNC, a bespoke tool probing system from Renishaw, the latest WAAM CMT material deposition system from Fronius and a 6 axis robot arm for tool changing, the machine is designed with Aerospace and defence manufacturing as the central market to manufacture components in excess of 800mm diameter or 600mm cube.
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