ABSTRACT
This paper presents a low-cost milling system composed of spindle mountable on a multi tool 3D printer equipped with maxwell kinematic coupling (E3D "ToolChanger" in this article) as well as two open-source software solutions for implementing a hybrid FFF/CNC manufacturing process. The first solution is the use of a traditional CAM software (FreeCad) for machining programming through the development of a dedicated post-processor. The second is an automatic layer-by-layer hybridization enabled by the software "SuperSlicer". This method requires no machining knowledge but only allows contouring operations. Results of experiments show that the spindle presented in this work is capable of successfully carrying out a hybrid process that significantly improves the surface roughness parameters, with an improvement factor of 10 for most parameters. An uniformization of surface roughness parameters was also observed in the construction direction and in the deposition/machining direction. The layer-by-layer hybridization yields the better results in terms of surface roughness. This is because the reduced depth of cut (equivalent to a printed layer) minimizes stress and temperature rise, resulting in highly favorable cutting conditions.
ABSTRACT
Nowadays, additive manufacturing of metallic materials is most often carried out using expensive and complex tools that leave the user with limited control and no possibility of modification. In order to make the printing of metal parts more accessible to small structures but also better suited for academic research, the use of a mixture of thermoplastic polymer and metal powder is a good solution as many granular feedstocks already exist for Metal Injection Molding applications. To perform the shaping process, the Fused Granular Fabrication 3D printing technology is set up by diverting the use of a feedstock in the form of pellets that are directly inserted into the print head. This solution, which is less costly, is implemented here by modifying a mid-range printer, the Tool Changer from E3D, and by making the hardware and software adaptations to mount a compact granulates extruder on it, which is also available on the market. The polymer portion present in the green part can then be removed in order to perform the heat treatments that will densify the powder by sintering and give a fully metallic dense object.
