Grant: Research Tools and Instruments

Hybrid Manufacturing (HM) is a term used to describe processes which combine additive manufacturing (3D printing - AM) with subtractive (machining) processes, enabling multiple operations on a single machine. HM processes combine the benefits of each of these manufacturing techniques while offsetting their short comings. For example, the majority of the parts made with 3D printing technology require post-processing to improve the surface finish (e.g. polishing, milling etc.). On the other hand, re-manufacturing of expensive parts requires the deposition of materials, which is a clear advantage of the combined HM technology. We are in the midst of a well-recognized break-through in 3D printing with polymers. However, the utilization of metals is of greater industrial interest and significance and has much more market potential, especially for Alberta. The equipment requested will boost the capabilities of advanced metal manufacturing at the U of A. Currently, the average price for quality commercial metal printers is more than $1,000,000. The high capital cost and slow production rate of 3D metal printers has limited their distribution and there are very few to be found at educational institutions. The availability of hybrid manufacturing facility at the University will open up new ways to collaborate with industries, but also provide easy access to train Highly Qualified Personnel (HQP) with diverse research programs including: 1) Integrating advanced technologies to deposit metals to produce complex parts with high precision and manufacturing intelligence, 2) Product strength enhancement by tool-path optimization, 3) Design, manufacturing and analysis of nasal airway for testing new nasal drug products, and 4) the investigation of: the interactions between wire and arc beam; the subsequent solidification of deposits; the formation of the microstructure; and the final mechanical properties of the components. In addition to the programs mentioned above, the equipment will also be used as a test/demonstration unit for manufacturing companies in Alberta. We are also planning to extend this facility to build a metal printing competence center and will collaborate with many other universities and industries across Canada. As part of the research program we will assess, industrialize and patent many products and integrated technology. The availability of the requested equipment will advances the state-of-the-art technology in a number of areas including: combined machining and 3D printing with low-cost objectives, re-manufacturing with shorter production times, strength enhancement and parts analysis of complex parts and critical alloy analysis for future innovative components. The requested equipment will accelerate the diversification of the Alberta economy and will supplement the growing shift of the local industries towards clean and green manufacturing.