Automated post machining process planning for a new hybrid manufacturing method of additive manufacturing and rapid machining

Purpose The purpose of this paper is to present a new method for automated post machining process planning for a hybrid manufacturing process. The manufacturing process is expected to generate complex functional parts by taking advantage of free form surface creation from additive manufacturing and high-quality surface finishing from CNC milling. Design/methodology/approach The hybrid process starts with additive manufacturing to generate a near net shape part with pre-defined machining allowances on surfaces requiring high quality surface or tight tolerances, along with integrated fixture geometry. The next step is to conduct automated machining process planning to determine critical parameters such as setup angle, tool selection, depth, tool containment, and consequently, the NC code to machine the part. Findings This method is shown to be a feasible solution for rapidly creating functional parts. The tests have been conducted to validate the method developed in this paper. Originality/value This paper introduces a new automated post machining process planning method for integrating additive manufacturing with a rapid milling process.