Application of a hybrid process for precision manufacture of complex components

In recent years, hybrid processes have drawn significant attention due to their ability to capitalise on the advantages of independent processes whilst minimising their disadvantages. However, production of highly accurate and complex structures, such as internal features, without assembly is still considered to be extremely difficult due to limited tool accessibility. This paper introduces a hybrid process entitled iAtractive, combining additive, subtractive and inspection processes. A novel process planning algorithm is proposed, taking into consideration, tool accessibility, production time and dimensional accuracy. A test part with internal features has been manufactured as one complete unit, demonstrating the efficacy of this hybrid process and the process planning algorithm.