Process planning for hybrid additive and subtractive manufacturing to integrate machining and directed energy deposition

Abstract This paper presents a hybrid additive and subtractive manufacturing method to integrate process planning considerations. This method could offer a new solution to deliver parts in a timely manner, minimizing inventory and material waste. The method essentially incorporates the base plate of additive manufacture into a final additive/subtractive manufactured product. Manufacturing begins with a base plate, where a set of subtractive steps will first create a portion of the design geometry. Next, the additive manufacturing process will be planned to create geometry on the machined base plate in two opposite directions, to minimize support structure and build height. Finally, a secondary machining process is planned to produce finished surfaces on the additively manufactured near net shape geometry. The work is implemented in the form of planning algorithms that integrate the aforementioned subtractive and additive process planning stages.