2-step hybrid additive-subtractive process
Parts are built up from bottom to top on a heated substrate, with temperatures ranging from room temperature to ~200C. Each layer is typically deposited as a combination of foils laid side by side rather than a single large sheet, as is typically practiced in sheet lamination processes. These layers are then trimmed using CNC milling to form the desired accuracy and geometry. This process works well with metals having low deformation resistance [4,5].
Step1: Ultrasonic seam welding
Step2: CNC milling
Low surface roughness and high dimensional accuracy
Not (yet) suited for components requiring supports
As it stands, on-going research is focused on this aspect and may result in technique improvement in the future.
Get Inside Metal Additive Manufacturing
1. S. Shimizu, H.T. Fujii, Y.S. Sato, H. Kokawa, M.R. Sriraman, S.S. Babu, Mechanism of weld formation during very-high-power ultrasonic additive manufacturing of Al alloy 6061 , Acta Materialia 74 (2014) 234–243
2. Wimpenny DI, Bryden B, Pashby IR (2003) Rapid laminated tooling. J Mater Process Technol 138:214
3. I. Gibson, D. Rosen, B. Stucker, Additive manufacturing technologies, Springer, p228