The proposal seeks to undertake the construction of a pre-production prototype “Combined
Additive Subtractive Hybrid” Rapid Manufacturing Machine the “STRATA-CASTER”,
evolved from a research project under the NWDA GRAND Proof of Concept Award Ref:
08/0068 completed 2010. It is also directed at enabling a manufacturing technology leap by
quickly bringing about a new generation of Hybrid manufacturing system to produce
functional parts rapidly, using a combination of laser additive layered metal deposition, a
unique 6 axis robotic manipulator and the latest developments in 3D machining, controlled by
the development of new user friendly software. The System will generate a near net shaped
layered Laser Deposited part in minutes from CAD model data, then using the same data
model and fixturing, subsequently machine the component to a precision finish. Traditional
subtractive manufacturing techniques are approximately 3000 times faster than additive metal
deposition systems. Unfortunately they generate up to 90% waste material processing a solid
billet. Layered deposition systems have alternative benefits, the ability to reduce considerably
the amount of material consumed in the manufacturing process, create near net shaped copies
of computer modelled component, designing of hollow parts, providing an ecological benefit
by reducing the fuel required to move them in automotive or aerospace application. Additive
systems usually produce parts slowly in batches using only 2.5D deposition, usually requiring
subsequent removal of supporting structures and additional machining of any precision
features using a subtractive process. A combination of the best attributes of three technologies
in a Hybrid system has the added benefits, accelerated production, 3D manipulation, reduced
manual intervention, pre-ops, setting up time, un/loading, reducing machining time, power
consumption and reduce waste will produce “Rapid Functional precision parts in One Hit”.