A Parallel Integrated Manufacturing System (PIMS) that combines robotic additive and subtractive manufacturing to deliver ready-to-use, net-shape parts, at the point of need, is proposed by VRC Metal Systems, LLC, as the solution to DONs request for developing a Shipboard Advanced Metal Manufacturing Machine. This hybrid AM system solution will primarily combine additive & subtractive functions, that will allow for parallel manufacturing of parts for DON in the shipboard environment and increase DONs warfighter readiness, distributed manufacturing capabilities, and self-sufficiency. PIMS will include a two (2)-robot system to carry out additive, deformation, non-destructive evaluation (NDE), build form scanning and dimensional measurement, and subtractive processes. This is a cost-effective solution, as the initial capital investment for the two (2) robots would be multiple times lower than the cost of integrating the deposition process into a modified CNC milling system. A wire arc additive manufacturing (WAAM) process will be used for the additive function of PIMS because of the process high deposition rate, acceptable feature resolution (low to medium), and ability to rapidly print small and large parts, in a cost-effective manner. A sensor package will be developed and attached to the PIMS cell to monitor the build process in-situ, notify the DON user when the process is outside the normal operating window, and perform corrective actions when needed. Subtractive manufacturing will be performed on the WAAM builds in the PIMS through the use of interchangeable machining tools in the tool holders. A set of additional tools for NDE, metrology, and deformation processing will be available within the PIMS cell and will be easily attached to the robotic arms for use.
Benefit: Numerous industries can benefit from the development of the proposed PIMS. There is a need for multi-functional, advanced metal manufacturing systems that can deliver ready-to-use parts, at the point of need, in a reliable and repeatable manner. Once the PIMS is fully developed and successfully used in DON, the system will be commercialized in the commercial sector and especially the aerospace industry. Currently there is significant interest in AM technologies, but the vast majority of processes have limitations of low deposit rates and a final product that has to go into another machine to be final machined. This system represents the pinnacle of AM technology by having the capability to produce a part to final or near final dimensions. Many of VRCs existing customers are interested in this capability and would be very willing to gain this capability especially at a moderate price point. VRC has also developed the capability to take processes like the cold spray process and build entire cells including gas supply, power generation, additive chamber, and control room into sea containers that can be shipped around the world, setup, then used anywhere. This PIMS capability will fit well with this mobile advanced manufacturing concept and can be rolled out especially the DOD circles.
Keywords: Sensors, Sensors, NDE, Advanced Metal Manufacturing Machine, additive manufacturing, Shipboard, WAAM, Parallel Integrated Manufacturing System (PIMS), Subtractive manufacturing
