Novel hybrid approaches for additive and subtractive manufacturing machines

Proposals should address the development of advanced All-in-one machines that enable the production of a part/product directly from a CAD model in a short time and without the need of post-processing steps. A variety of Additive Manufacturing technologies and different materials can address this challenge by means of new and/or innovative processes.

• Develop new machine concepts and designs into a single set-up processing and process control.
• Full integration and automation of the subtractive and additive processes in the machine
• Increased build rate of the machine in comparison to the separate processes
• Production of parts/products that are functional and with the final desired accuracy, surface-finish and tolerances and material efficiency
• Properties of the new components after the manufacturing process

The proposal must include at least one demonstrator in real industrial settings in order to show the industrial viability of the solution.

Activities are expected to focus on Technology Readiness Levels 4 to 6.

The involvement of SMEs is encouraged.

The Commission considers that proposals requesting a contribution from the EU between EUR 3 and 5 million would allow this specific challenge to be addressed appropriately. Nonetheless, this does not preclude submission and selection of proposals requesting other amounts.

Manufacturing has been using for the production of goods and wares many different processes that can be classified as subtractive or additive processes. Traditional machines have been normally focused on only a single type of these processes but there is a new generation of machines that combines the features of individual manufacturing processes into a single platform.

These hybrid manufacturing processes can enable a high-value and sustainable manufacturing by keeping the advantages of the single processes in a single machine whilst reducing their disadvantages. Nevertheless, the enhanced features of the hybrid machines bring as well an increasing process complexity and higher costs of production that impact the final price in the market of the produced items. High added value products with complex structures can balance out those production costs.

New hybrid machines, equipped with both subtractive and additive manufacturing technologies, can be a game changer to create new opportunities and applications for Additive Manufacturing (AM). The great potential of AM is in most of the cases limited by the subtractive post-processing steps needed to ensure optimal tolerances and surface finish. These hybrid combinations can also enable the production of larger items than in AM single machines and have a large potential for repair applications.

The developed novel hybrid approaches should lead to a remarkable impact in the following terms:

• 20% reduction in time and cost, with respect to the current additive and subtractive processes.
• 15% increase in productivity for high-volume AM production, with respect to the current additive and subtractive processes.
• More flexibility and robustness of the machines to adapt with customisation and changing market needs
• Reduction of inventory because of the making of products on-demand
• Reduction of work floor space
• Create localised manufacturing environments and reduce supply chains length
• Contributions to standardisation and certification for new hybrid procedures.

The role of SMEs and their potential as manufacturers and end-users for the developed machines needs to be considered, in order to ensure the access to existing and new markets.

Proposals should include a business case and exploitation strategy, as outlined in the Introduction to the LEIT part of this Work Programme.

This topic complements other call topics in this area funded under FoF-13-2016