What if it were possible to combine additive and formative manufacturing in a single system? While many machines can change tool heads, offering hybrid production, a team of researchers from the Johns Hopkins Whiting School of Engineering has developed a method that combines quality and speed. Called Hybrid Formative-Additive Manufacturing (HyFAM), this hybrid approach uses an extrusion system to 3D print complex geometries that can then be filled by molding or casting. The marriage of these two processes is particularly advantageous: it is possible to create complex shapes with greater detail where required, while at the same time being able to fill less precise areas more efficiently.
As we all know, 3D printing still faces a number of obstacles, including speed and defects such as inefficient filling, warping and internal voids. Indeed, while additive manufacturing offers a high level of detail, this is not always required throughout the part. Team member Nathan Brown explains: “Additive manufacturing offers significant detail, but when you use a small nozzle to achieve it, the entire process slows down. This becomes a real hinderance [sic] in parts with large internal features and widely-varying feature sizes.”
The HyFAM method combines the advantages of additive manufacturing with those of formative manufacturing
The researchers, led by Professor Jochen Mueller, have therefore developed an extrusion system with two reservoirs: the first is used to deposit the desired material layer by layer, like an FDM 3D printer. The second is used to fill the model created with another material. This filling stage can be used for one, several or all layers.
Various tests have been carried out with different materials. The researchers explain that they can print on ceramics, silicone, clay and even metals. The HyFAM method is also multi-material, as the researchers are able to precisely control rheological properties. To sum it up in one sentence: the process involves 3D printing the details and completing the part by injecting material. The result, according to the team, is a process that is 10 to 20 times faster, while at the same time more precise, since all the internal voids inherent in layering are eliminated.
HyFAM is compatible with several materials
Professor Jochen Mueller adds, “HyFAM is less advantageous for highly intricate, uniform objects, but its strengths in combining speed, material flexibility, and design complexity make it a promising solution for a wide variety of industries, from construction to soft robotics.”
The process could be particularly interesting for applications where mass customization is required, but also for designing parts that feature detailed areas and others that do not. One thing’s for sure, this method is full of promise, and we’ll be sure to keep you posted on the latest advances! To find out more, click HERE.
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*All Photo Credits: Johns Hopkins Whiting School of Engineering