The Sum of Its Parts: CAM Plus Additive Equals Powerful Hybrid Manufacturing

Traditionally, manufacturing methods have been subtractive, centered around material removal. But over the past two decades, additive manufacturing (AM) has become increasingly prevalent in industry. The advent of more globally produced and affordable materials helped drive the technology’s accessibility to both manufacturers and consumers.

The combination of additive and subtractive manufacturing on the same machine is known as hybrid additive manufacturing. According to a report from Grand View Research, Inc. (San Francisco, CA), the global hybrid additive manufacturing market was valued at $193 million in 2022 and is expected to grow by 22% between now and 2030. That’s big news, but probably not a surprise to those familiar with the technology’s capability and flexibility.

CAM + AM = Possibility

Did you know that computer-aided manufacturing (CAM) and AM working in tandem can be used to create new parts or repair existing ones? Applications for this technology are mainly within the aerospace, medical, and automotive industries, but the list of applications continues to grow. One example is the case of tool and die repair—parts that are extremely costly to produce from scratch. Blade repair is another common application. With hybrid CAM and AM technology, a damaged part can now be repaired with its original material and properties and be machined down to create a seamless fix. There’s a lot of value here.

CAM and AM hybrid technology is on the rise, which is great news for manufacturers. But what does this mean for CNC programmers and machinists who have built their careers around subtractive manufacturing? What kind of training and skills are needed to use cutting-edge AM methods?

Thankfully, software developers are creating products that mesh these two technologies into powerful, user-friendly platforms. For example, additive manufacturing software developed by one of our partners can be integrated into Mastercam CAD/CAM software. APlus’ (CAMufacturing Solutions Inc., Windsor, ON) toolpaths and features were created specifically for AM. The software allows us to control CAM and AM in CNC machine tools that have integrated both technologies within the same machine. The flexible software runs with Mastercam and uses the same engine to optimize toolpaths for direct energy deposition (DED).

Make new Parts, or Keep the Old

In the case of part repair, beginning the process with an accurate model is crucial. The model must be of the original part, or reverse engineered from the broken part. It is then imported into our CAD/CAM software and the rest of the process is the same as creating an original part. APlus deposits material on the part (the deposit area is larger than the final shape of the geometry). Next, a traditional subtractive machining process is applied to remove material and blend it back to the original part shape.

Producing a new part is similar to programming a traditional file in Mastercam. A model is designed, and APlus software creates output to drive the additive head on the CNC machine. Mastercam, in conjunction with APlus, simulates both material deposition and machine motion. Relevant parameters can be adjusted, and a user can switch between additive and subtractive machining to create desired geometries.

To create a prototype, special fixturing, or a part requiring geometry that cannot be machined with subtractive methods, combining CAM and AM could be a solution. Or, for a part that needs an interior feature that must be machined, layers of additive can be deposited and built up, machined, then built up again with more additive.

Also, a part can be printed slightly oversized, or near net shape, then machined away to net shape. Features that could not be reached with traditional methods alone are finished at the correct tolerance. In addition, combining AM with 5-axis milling capabilities can create interior square corners or features that a subtractive milling tool cannot reach. Something to keep in mind when considering AM is machine speed. Additive manufacturing runs at approximately 20% the speed of CNC machining. Material is deposited slice by slice, layer by layer. Due to thermal expansion and the cooling rate of the additive, layers must cool before being machined, otherwise part accuracy could be compromised.

With such a growth in its popularity and its range of applications, count on seeing increased demand for additive manufacturing, especially in mid- to small-size shops that want to take advantage of the technology. The cost of entry has gone down quite a bit over the last few years, so AM is more accessible than ever. Because more companies that develop the technology are getting into the field, there could soon be a lower cost of entry for hardware as well.

If you are looking for ways to add value to your shop, CAM plus AM is worth considering. A manufacturer that has both subtractive and additive manufacturing capabilities may be better prepared for whatever jobs come along.

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