More Than Time Saved How Automated Rework on 3D-Printed Parts Succeeds

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Fotec Research and Technology Transfer at the University of Applied Sciences Wiener Neustadt has succeeded in making the rework of additively manufactured components more economical through the so-called Hirtisation process.

Fotec Research and Technology Transfer, the research company of the University of Applied Sciences Wiener Neustadt, has developed significant contributions for the integration of additive manufacturing into industrial process chains in the international joint project "Ad-Proc-Add II." The focus was on automated post-processing using Hirtisation. This is a combination of chemical, dynamic electrochemical, and hydrodynamic processes that do not require mechanical machining. The liquid media-based Hirtisation also treats deep cavities and undercuts on printed parts, allowing for the removal of support structures. Many parts can be simultaneously Hirtised in the machines.

Hirtisation Has Been Further Developed

A highlight of Fotec's contribution, as further noted, was the advancement of Hirtisation. Building on the results of a previous project, targeted machining strategies for materials such as Ti6Al4V and 1.4404 (stainless steel) were developed. By adjusting PBF-LBM process parameters (PBF: Powder Bed Fusion; LBM: Laser Beam Melting), machining allowances of only 180 to 550 micrometers could be defined. This is considered an important step towards material-saving, automated post-processing of 3D-printed parts. At the same time, surface roughness of Ra ≤ 5 micrometers was achieved, enabling precise functionalization of such components. The project also pursued the characterization of additively manufactured surfaces and the development of databases for process optimization.

Surface Analysis and Data Management

Fotec conducted extensive investigations into the surface integrity of additively manufactured components. The research analyzed how different PBF process parameters, build orientations, and intermediate treatments affect the final surface properties. A particular focus was on the interaction with processes such as shot peening, heat treatment, and CNC form grinding. The resulting surface matrix provides a solid foundation for the targeted combination and optimization of additive and subtractive process steps.

A significant contribution to digital continuity in this area, as emphasized, was the development of a cross-process data management system, created in the current project by the Institute of Manufacturing Technology and Photonic Technologies at TU Wien together with project partners. A hybrid CAM system was prototypically supplied with multi-sensor-supported real-time data, from which tool paths were automatically generated. By integrating sensor technology, material data, and geometry information, an "intelligent" adaptive CAM control system was established, marking a milestone for the automation of complex ASM process chains (Additive-Subtractive Manufacturing).