Hybrid 3D Metal Printing Process Optimization using ML and AI

Metal additive manufacturing (AM), or 3D printing, typically builds parts layer-by-layer using an additive process. However, many AM techniques often require support structures, and the final parts may not meet the required dimensional accuracy or surface finish directly from the printer. This process necessitates a separate subtractive process, such as CNC machining, to achieve the desired quality. Our innovative hybrid metal 3d printing technology addresses these limitations by combining additive and subtractive processes within a single machine. This technology eliminates the need for separate machines and post-processing steps, streamlining production and reducing overall lead times. 3D Hybrid metal printer developed at Western Michigan University combines two manufacturing methods - additive manufacturing and Computer Numeric Control (CNC) machining. The additive process uses the gas metal arc welding (GMAW) method to deposit each metal layer along a path controlled with CNC. The subtractive machining process is performed on the same CNC-controlled machine. The 3D Hybrid metal printer iterates between these two processes, adding material with welding and then using CNC machining to refine the surface. These additive/ subtractive processes are repeated until the final 3D object is complete to achieve the essential geometrical and quality requirements, the same as machining with a typical CNC machine. Traditional manufacturing processes have been refined for many years to guarantee defect-free parts, while 3D printing often requires manual intervention and might produce imperfect layers. To address these issues, we developed an automated 3D metal printing process using sensors for feedback during the printing process and machine learning/artificial intelligence (ML/AI) algorithms to optimize the printing. This process aims to reduce costs, printing time, and waste while achieving first-time printing success with the same quality as traditional methods. Keywords: hybrid metal 3D Printing, additive manufacturing, cnc machining, machine Learning, Artificial Intelligence