The research project HyFAS aims to industrialize and automate the hybrid laser powder bed fusion (LPBF) technique for metallic components. This innovative approach seeks to enhance manufacturing efficiency, reduce costs, and improve the quality of hybrid parts by addressing integration challenges between conventional and additive processes.
LPBF is renowned for its resource efficiency and capability to create intricate metallic components. However, precise alignment of additive structures onto pre-formed parts is often problematic, leading to failed prints. To improve the accuracy of the alignment, a stereo vision system has been developed for seamless integration into any LPBF machine. This system accurately measures the 6D pose of base components, ensuring proper alignment and enabling additive parts to be printed with a positional accuracy of 0.1 mm.
Moreover, the stereo system facilitates partial automation of substrate plate levelling and powder level measurement, enhancing operational efficiency. The successful implementation of this technology paves way for high-precision and high-performance production, thereby unlocking new opportunities in hybrid additive manufacturing.
