Abstract
Subtractive manufacturing (CNC machining) has high quality of geometric and material properties but is slow, costly and infeasible in some cases; additive manufacturing Rapid Prototyping (RP) is just the opposite. Total automation and hence speed is achieved in RP by compromising on quality. Hybrid Layered Manufacturing (HLM) developed at IIT Bombay combines the best features of both these approaches. It uses arc welding for building near-net shapes which are finish machined to final dimensions. High speed of HLM surpasses all other processes for tool making by eliminating NC programming and rough machining. The techno-economic viability of HLM process has been proved through a real life case study. Time and cost of tool making using HLM promises to be substantially lower than that of CNC machining and other RP methods. Interestingly, the material cost in HLM was also found to be lower. Synchronisation of this two-step process offers a new accelerated way of building metal tools and dies. HLM can also be used as a cheaper retrofitment to any three or five axis CNC milling machine or machining centre.
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