Short answer

Integrate subtractive post-processing into the design and manufacturing strategy from the outset when using additive manufacturing for metal parts.

Field: Final Production
Source: Journal of Machine Engineering (2023)
Method: Literature Review
Evidence: Strong effect

Integrating additive manufacturing with subtractive post-processing is crucial for achieving the required geometric tolerances and surface finishes in complex metal parts. This final production research insight is drawn from a 2023 study published in Journal of Machine Engineering. Using Literature review, researchers explored how this design variable affects real-world outcomes. The key design takeaway: Integrate subtractive post-processing into the design and manufacturing strategy from the outset when using additive manufacturing for metal parts.

Study

Final ProductionRecentStrong effect

Additive-Subtractive Process Chains Enhance Geometric Accuracy and Surface Quality in Metal Part Production

Integrating additive manufacturing with subtractive post-processing is crucial for achieving the required geometric tolerances and surface finishes in complex metal parts.

Journal of Machine Engineering · 2023

Key Findings

01Almost all additively manufactured metal parts require post-processing to meet geometric and surface quality demands.
02Additive-subtractive process chains are essential for producing complex, function-integrated metal parts.
03Interactions between additive and subtractive processes occur at both macroscopic geometric and microscopic material structure levels.

Application

Design takeaway

Integrate subtractive post-processing into the design and manufacturing strategy from the outset when using additive manufacturing for metal parts.

How to apply

When designing a complex metal component for additive manufacturing, explicitly map out the necessary post-processing steps, including machining and surface finishing, and factor their impact on the final dimensions and material properties into the design.

Project actions

01When selecting materials for 3D printing, consider how they will behave during subsequent machining.
02Document the post-processing steps clearly in your design project, explaining why each step is necessary.

Method & Evidence

AimWhat are the key influences and interactions within additive-subtractive process chains for metal part manufacturing?

MethodLiterature Review

ProcedureThe paper reviews recent research findings on additive-subtractive process chains, covering various additive manufacturing methods (PBF-LB, LMD-p, WAAM, LMD-w/WLAM), intermediate steps (heat treatment, shot peening), and subtractive post-processing techniques.

ContextMetal additive manufacturing and subsequent subtractive post-processing.

Variables

IV["Type of additive manufacturing process","Type of subtractive post-processing"]

DV["Geometric accuracy","Surface roughness","Material properties"]

CV["Material type","Part complexity","Environmental conditions during processing"]

Strengths & Limitations

Strengths

+Comprehensive overview of current research in additive-subtractive chains.
+Addresses both macroscopic and microscopic influences.

Limitations

The specific post-processing requirements can vary significantly based on the chosen additive manufacturing technology, the material used, and the desired final application tolerances.

Reliability & validity

The reliability of findings depends on the consistency of the reviewed studies. Validity is strengthened by the breadth of additive and subtractive processes considered.

Think critically

To what extent can advancements in additive manufacturing technologies reduce the need for subtractive post-processing in the future?

Design Principles

"Design for Additive-Subtractive Manufacturing: Plan for post-processing to achieve final part specifications."

For designers and engineers, understanding the necessity of post-processing in additive manufacturing is vital for realistic design for manufacturing. It influences material selection, part complexity considerations, and the overall production cost and timeline.

What This Means for Your Design

If you 3D print metal parts, you almost always have to machine them afterwards to make them accurate and smooth enough for use.

How to use in your project

1.Reference this paper when discussing the limitations of pure additive manufacturing and the necessity of post-processing for achieving design specifications in your design project.

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Quick Cite

Paragraph starter

The integration of additive and subtractive manufacturing processes is critical for achieving the required geometric tolerances and surface quality in complex metal parts. Research indicates that nearly all additively manufactured components necessitate post-processing, highlighting the importance of considering the entire additive-subtractive process chain from the initial design phase to ensure functional and accurate end products.

Source

Journal of Machine Engineering

The Additive-Subtractive Process Chain - a Review

journal · 2023

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Questions About This Research

What does the research say about additive-subtractive process chains enhance geometric accuracy and surface quality in metal part production?: Integrate subtractive post-processing into the design and manufacturing strategy from the outset when using additive manufacturing for metal parts. Evidence: Journal of Machine Engineering (2023).
Why does "Additive-Subtractive Process Chains Enhance Geometric Accuracy and Surface Quality in Metal Part Production" matter for design?: For designers and engineers, understanding the necessity of post-processing in additive manufacturing is vital for realistic design for manufacturing. It influences material selection, part complexity considerations, and the overall production cost and timeline.
How can designers apply this research?: Integrate subtractive post-processing into the design and manufacturing strategy from the outset when using additive manufacturing for metal parts.
What were the main findings?: Almost all additively manufactured metal parts require post-processing to meet geometric and surface quality demands.. Additive-subtractive process chains are essential for producing complex, function-integrated metal parts.. Interactions between additive and subtractive processes occur at both macroscopic geometric and microscopic material structure levels.
What research method was used?: Literature Review.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2023 journal from Journal of Machine Engineering.
What should I do differently in my next project?: When designing a complex metal component for additive manufacturing, explicitly map out the necessary post-processing steps, including machining and surface finishing, and factor their impact on the final dimensions and material properties into the design.
What are the limitations?: The review focuses on metal additive manufacturing and may not encompass all material types or emerging additive technologies.