Improvement of Dimensional Accuracy of 3-D Printed Parts using an Additive/Subtractive Based Hybrid Prototyping Approach

At present, two important processes, namely CNC machining and rapid prototyping (RP) are being used to create prototypes and functional products. Combining both additive and subtractive processes into a single platform would be advantageous. However, there are two important aspects need to be taken into consideration for this process hybridization. First is the integration of two different control systems for two processes and secondly maximizing workpiece alignment accuracy during the changeover step. Recently we have developed a new hybrid system which incorporates Fused Deposition Modelling (FDM) as RP Process and CNC grinding operation as subtractive manufacturing process into a single setup. Several objects were produced with different layer thickness for example 0.1 mm, 0.15 mm and 0.2 mm. It was observed that pure FDM method is unable to attain desired dimensional accuracy and can be improved by a considerable margin about 66% to 80%, if finishing operation by grinding is carried out. It was also observed layer thickness plays a role on the dimensional accuracy and best accuracy is achieved with the minimum layer thickness (0.1 mm).