Combined Laser Additive Manufacturing and Subtractive Surface Finishing (CLASS)

Laser powder bed fusion (PBF) is an emerging manufacturing approach to produce net shapes
and functional products directly from computer aided three dimensional designs. The parts are
built by the consecutive application and consolidation of material layers. In order to become
more widely accepted within manufacturing, there are still considerable hardware associated
issues which need to be resolved including but not restricted to; residual stress, surface
texture and methodologies for surface finishing, these problems are exacerbated as the
process gets faster and is applied to larger parts. The ability to capture in -- process data by
digital integration will further validate the acceptance of the AM process in the production of
parts which are controlled by regulatory standards, where process records are required.
The aim of this project is to produce a metal AM machine platform, the subsystems of which are
scalable in future to meter class, which is capable of reducing the residual stresses developed
during the AM build, and that will perform in process non-contact finishing on parts as they are
built. Multiple machines will also be digitally connected and monitored via sensors for real-time
insights across a cohort of globally connected manufacturing facilities.