Page 64 - MSAM-2-4

Materials Science in

Additive Manufacturing

ORIGINAL RESEARCH ARTICLE
Base shape generation and optimization for

multi-axis hybrid additive manufacturing

1
Zhiping Wang , Zhen Hong , Sihao Deng , Yicha Zhang *, and Alain Bernard 1
1
3
2
1 Ecole Centrale de Nantes, LS2N, CNRS UMR 6004, Nantes, 44321, France
2 UTBM - Université de Technologie Belfort-Montbéliard, ICB-PMDM, CNRS UMR 6303, Sevenans,
90400, France
3 UTBM - Université de Technologie Belfort-Montbéliard, ICB-CO2M, CNRS UMR 6303, Sevenans,
90400, France

Abstract

Hybrid additive manufacturing (HAM) processes combine the advantages of both
additive and non-AM processing to achieve an improvement on quality, cost, and a
good quality-cost balance. The non-additive manufacturing process is able to build
the physical component of a computer-aided design model from zero or an existing
relatively simple subvolume, called base shape in this paper. Hence, if the processing
start point is an existing subvolume, how to determine an optimal base shape to
save printing time, avoid manufacturing constraints and ensure component quality
is an open question in the process planning. Nevertheless, this topic has rarely
been investigated. Therefore, in this paper, we propose an optimization method
using model skeleton-based decomposition and evolutionary computation. A set
of generic evaluation criteria are defined for alternative evaluation. We also present
*Corresponding author:
Yicha Zhang two case studies in this paper for validating the proposed method and conclude that
(yicha.zhang@utbm.fr) sequential HAM processes have a wide application potential.
Citation: Wang Z, Hong Z, Deng
S, Zhang Y, Bernard A, 2023, Keywords: Base shape; Process planning; Hybrid additive manufacturing
Base shape generation and
optimization for multi-axis hybrid
additive manufacturing. Mater Sci
Add Manuf, 2(4): 2103. https://doi.
org/10.36922/msam.2103 1. Introduction
Received: October 24, 2023
As the process and material development continues to advance, additive manufacturing
Accepted: November 13, 2023 (AM) emerges as a key technique in functional manufacturing . Its capacity to manufacture
[1]
Published Online: December 22, 2023 parts with complex surface and internal geometries by adding layers of materials without
the use of tooling or fixtures enables it to be a promising processing candidate for high-
Copyright: © 2023 Author(s).
This is an Open-Access article value component fabrication, and the non-linear relationship between its printing cost
[2]
distributed under the terms of the and the component complexity makes it an attractive avenue for manufacturing parts . In
Creative Commons Attribution addition, AM also provides freedom to design, offers mass personalization to consumers,
License, permitting distribution,
and reproduction in any medium, removes the need for parts shipping and warehouse storage, and reduces waste and energy
provided the original work is consumption [3,4] . However, compared with traditional processing technologies, limitations
properly cited. still exist in additive manufacturing processes, such as poorer dimensional accuracy
Publisher’s Note: AccScience and surface quality [5,6] , limited materials, and relatively long printing time for some
Publishing remains neutral with applications , especially for metallic AM processes. It is not realistic to use AM only for
[7]
regard to jurisdictional claims in
published maps and institutional select attributes such as high accuracy and superior performance in fabrication while not
affiliations. considering the feasibility and high-cost problems this technique is tied to. For example,

Volume 2 Issue 4 (2023) 1 https://doi.org/10.36922/msam.2103