On April 21, 2020, a joint research project funded by the German Federal Ministry of Education and Research (BMBF) will develop a new type of efficient modular hybrid manufacturing system.
It is reported that this project is named ProLMD. The project members are composed of 8 partners. It was launched four years ago. The initial goal was to produce a new hybrid manufacturing process that would compare the traditional method with the laser material deposition (LMD) additive manufacturing process. Combine.
One of the partners, Jan Bremer, a scientist at the Fraunhofer Institute for Laser Technology, explained. “Our goal is to develop an economical and robust system technology for the LMD process based on a combined arm robot, and integrate it into the process chain of hybrid manufacturing. We are following the process chain of robot-based hybrid rapid prototyping manufacturing Go forward and study the various technologies needed for this. The content covers everything from processing heads, robots and shielding gas systems to welding processes, quality assurance and software.”
Hybrid additive manufacturing production
In the past four years, some project partners have begun to integrate rapid prototyping manufacturing technologies in their existing process chains. MTU Aero Engines has been using LMD to add functional components to traditionally manufactured engine parts; Airbus has reinforced some of its components with 3D ribs; Mercedes-Benz has added LMD tools to the stamping tools on its body production line head.The actions of these partners are in line with the project’s vision, which is to use3D printingTechnology locally strengthens or transforms traditionally manufactured components.
Bremer added: “These examples illustrate our understanding of hybrid manufacturing. We flexibly combine the advantages of different manufacturing processes to form a continuous process chain.”
ProLMD project
It is reported that the project has developed a single modular hybrid manufacturing cell, which is a multi-axis KUKA robotic arm with LMD tool head, designed to be easily integrated into the existing process chain. In order to achieve maximum application flexibility, partners are working to promote powder and wire as materials for additive manufacturing. According to Bremer, the focus of the project is to be able to process larger and more complex parts with a weight of up to 1.2 tons and a diameter of up to 2 meters.
Partners have clear responsibilities in the project. For example, KUKA serves as the project manager, responsible for the unit integration of the robot, and Laserline is responsible for the design and development of laser beam sources and optical devices.
The project partners are also working on a smaller secondary project in addition to the hybrid manufacturing cell-a more compact robotic cell for hybrid additive manufacturing production. Compared with the large-scale system, the second robot will be more cost-effective and is designed to meet the needs of small and medium-sized enterprises. The 3.1-meter-long robotic arm has been reduced to only 2 meters, and the load capacity of 90 kg has also been reduced to 60 kg. Smaller robots will also only focus on the LMD of powder materials, losing the ability to work with wires.
Hybrid production absorbs the advantages of traditional manufacturing and rapid prototyping manufacturing, and can achieve more effective results.Last year, well-known machine tool manufacturers
DMG MORI company launched LASERTEC 125
3D hybrid rapid prototyping manufacturing system. This five-axis laser deposition welding (LDW) system is designed for the maintenance, repair and production of large industrial parts.Recently, the Melbourne-based CNC grinding machine manufacturer ANCA has also developed its own hybrid3D printingSystem for manufacturing customized machining tools.
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