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Results for “subtractive manufacturing”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Volumetric Subtractive Manufacturing

Manufacturing small negative features has been extremely challenging in whole additive manufacturing (AM) field. Due to overcuring, diffusion and refractive index increase, the achievable smallest negative feature and fidelity is always worse than the smallest positive one using AM methods. Additionally, attempting to print multi-scale feature sizes in the same exposure has proven to be challenging in DLP printing due to diffusion and inhibition. To address these challenges, we have developed a hybrid additive and subtractive manufacturing approach on a DLP platform with a dual-wavelength photopolymers to be able to print multi-scale features and small negative features with accuracy. And we also have demonstrated a first-of-its-kind Volumetric Subtractive Manufacturing by fabricating non-planar double helix fluidics by photo-degrading polymers. This work has the potential to shift the paradigm of DLP AM techniques by incorporating subtractive manufacturing as a new degree of freedom for enhancing the achievable print resolution and enabling corrective and adaptive manufacturing.

42 ENGINEERING↗
DOE OSTI2023

Glass Additive and Subtractive Manufacturing of a Fiber Optic Rotary Encoder for Downhole Pressure Sensing

This article presents a fiber optic rotary encoder-based pressure sensor for downhole applications. The rotary encoder, which is composed of an encoding pad and an all-glass optical fiber sensing head, converts the rotation angles of a pressure transducer to digital codes. The optical fiber only serves as the telemetry channel to directly transmit the data in digital format such that the environmental temperature influence and the long-time drift are minimized. The glass additive and subtractive manufacturing (ASM) techniques are used to embed the multichannel optical fibers into a bulk-fused silica glass substrate. Because the fused silica glass shares a similar material property to the optical fiber (e.g., thermal expansion coefficient), the optical fiber sensing head is well sealed and fixed even at an elevated temperature. The picosecond laser blackening technique is used to fabricate the high reflectivity contrast encoding pad with high accuracy. Here, the proposed pressure sensor was manufactured and experimentally verified to have a signal-to-noise ratio (SNR) of 23 dB and a linear pressure response with a root-mean-square error (RMSE) of 0.37. During the 400-h 250 °C long-term stability test, there was no digital code variation. In addition, a mathematical model to study the relationships between the sensor’s performances and design parameters was established. According to the model, a 12-bit encoder (0.02% pressure sensitivity) can be achieved with a radius of 20 mm.

02 PETROLEUM↗
DOE OSTI2025

Hybrid Additive and Subtractive Manufacturing of Dual‐Wavelength Photopolymer Thermosets

Additive manufacturing (AM) techniques such as digital light processing (DLP) AM and stereolithography enable the production of highly complex structures with speed and ease as not previously possible. However, many traditional thermosetting photopolymers used in these processes result in a permanently crosslinked structure incapable of being broken down or modified without the use of energy-intensive processes such as mechanical machining or ablation. To overcome this limitation, this production is described of thiol-ene photopolymer thermosets with dual-wavelength photopolymerization and photodegradation reaction pathways. The dual wavelength selectivity of the polymerization (405 nm) and degradation (365 nm) processes, combined with dual-wavelength DLP AM technology, enables hybrid manufacturing with the ability to add and sequentially subtract material with excellent spatiotemporal control. 2D lithographs and complex 3D architectures with soft elastomeric properties are produced with resolutions as small as 50 µm. Furthermore, the ability to selectively subtract supports from 3D printed structures with deliberate and accurate control is demonstrated. In conclusion, the ability to correct or modify existing structures enables a new paradigm of adaptable materials for corrective manufacturing techniques and temporary structures.

3D Printing↗
DOE OSTI2024

Positioning Accuracy in a Concurrent Robot-CNC Hybrid Manufacturing System

Abstract Additive manufacturing (AM) has gained notoriety for offering advantages over traditional manufacturing methods, such as increased design complexity and flexibility. However, it has not found widespread use beyond rapid prototyping. One hindrance to the acceptance of AM processes in industry is the time and cost of fabrication per component. While metal AM by itself can be inexpensive, extra manufacturing steps in the form of subtractive manufacturing (SM) may need to be performed to reach final part tolerances, leading to hybrid additive-subtractive manufacturing (HASM) of a part, which increases time and cost. A potential area to reduce cost is through increasing the efficiency of the HASM process by conducting additive and subtractive manufacturing simultaneously. Usually, HASM is performed in a process where AM is completed in one machine or cell and transferred to another machine or cell for SM in a sequential assembly line process. This efficiency decreases part cost, but high aspect ratio parts or parts with internal geometry that require interleaved additive deposition and machining cannot be produced. One unexplored solution to simultaneous HASM that allows for interleaved operations is to operate the deposition head and machining spindle concurrently within the same machine envelope, known as concurrent HASM (CHASM). In this type of process, both AM and SM occur simultaneously on a batch of small parts or a single large part, maintaining a high efficiency without sacrificing the full range of complex geometries that AM allows for. A potential approach to the single-machine method could be to combine a robot and mill within the same envelope. A challenge to this approach, however, is control of both systems. Most machine controllers have limited external communication or, if a robot has been integrated, only offer movement of either the robot or mill at any given time. As a result, systems must pause either the AM or SM process to switch between them rather than working simultaneously. The present work investigates the positional accuracy of such a CHASM system comprised of a robotic arm and a 3-axis mill. Open-loop tests with limited communication between machines are performed on the system to verify positional error during concurrent robot-mill movements. Under certain conditions, it is demonstrated that position error can stay within 2 mm for the duration of a single layer; however, these tests show that, generally, the open-loop positioning performance of the system is inadequate for CHASM without part-specific hand-tuning of parameters. Based on these results, a set of requirements for successful robot-CNC CHASM is proposed for future integrations.

Goodwin, Jesse↗
DOE OSTI2023

Review of in situ process monitoring for metal hybrid directed energy deposition

Hybrid manufacturing, or the combination of additive and subtractive manufacturing within a single build volume is transforming the way products are being fabricated. Additive manufacturing confers unprecedented freedom of design and reduced material usage while enabling serial customization. Subtractive manufacturing provides superior surface finish and improved dimensional accuracies. Interwoven, these two digital manufacturing paradigms are enabling the rapid manufacturing of complex, highly accurate, and customized geometries in a diversity of high-performance alloys. In situ monitoring, heavily relied upon in either additive or subtractive, becomes even more crucial with the interplay of the two processes in a single combined build sequence. Moreover, challenges that do not exist in either process alone can now have a dramatic impact on final part quality: (1) a large amount of heat is generated during additive manufacturing deposition, which is primarily dissipated into the machine tooling and impacts accuracy by deforming the material and causing misaligned machining; (2) microstructure, mechanical properties, and residual stresses are the result of the complex thermal histories generated by additive manufacturing and can impact subsequent cutting performance. This comprehensive review considers previous research in monitoring and providing closed-loop control in both additive and subtractive manufacturing separately and then considers the implications of the effectiveness of these monitoring techniques when additive and subtractive processes are integrated together.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Toolpath considerations for hybrid additive manufacturing

Hybrid additive manufacturing combines both additive and subtractive manufacturing processes to fabricate geometrically complex, dimensionally accurate parts that are difficult to make using either additive or subtractive manufacturing alone. Industrial applications for hybrid additive manufacturing include direct manufacturing (building whole parts), feature addition (adding onto existing parts), and remanufacturing or repair operations. To coordinate the additive and subtractive processes, computer-aided manufacturing (CAM) software must generate distinct toolpaths for each process. Each application requires different considerations and inputs when generating the toolpaths. For example, when building a part with an internal cavity that would otherwise be unmanufacturable due to reach or access limitations, a CAM must determine which layer(s) of deposition are appropriate to machine to create the internal cavity. This chapter explores the area of toolpath generation for hybrid manufacturing by discussing the necessary considerations that are unique to a hybrid process.

Feldhausen, Thomas↗
DOE OSTI2023

A framework for hybrid manufacturing cost minimization and preform design

Here, this paper describes preform design optimization in hybrid additive-subtractive manufacturing. In hybrid manufacturing, the question of what form and what geometry the additive preform should take has largely been a matter of intuition and experience, or trial and error. The choice of a more optimal preform depends on the target parameters, such as stiffness, cost, or lead time. We demonstrate a framework for preform optimization using static stiffness, and then the combined cost of additive and subtractive manufacturing, while respecting stable cutting conditions for the tool-part combination. The procedure is illustrated by comparing three preform geometries for a thin wall.

42 ENGINEERING↗
DOE OSTI2021

Surface Qualification Toolpath Optimization for Hybrid Manufacturing

Hybrid manufacturing machine tools have great potential to revolutionize manufacturing by combining both additive manufacturing (AM) and subtractive manufacturing (SM) processes on the same machine tool. A prominent issue that can occur when going from AM to SM is that the SM process toolpath does not account for geometric discrepancies caused by the previous AM step, which leads to increased production times and tool wear, particularly when wire-based directed energy deposition (DED) is used as the AM process. This work discusses a methodology for approximating a part’s surface topology using on-machine contact probing and formulating an optimized SM toolpath using the surface topology approximation. Three different geometric surface approximations were used: triangular, trapezoidal, and a hybrid of both. SM toolpaths were created using each geometric approximation and assessed according to three objectives: reducing total machining time, reducing surface roughness, and reducing cutting force. Different prioritization scenarios of the optimization goals were also investigated. The optimal surface approximation that yielded the most improvement in the optimization was determined to be the hybrid surface topology approximation. Furthermore, it was shown that when the machining time or cutting force optimization goals were prioritized, there was little improvement in the other optimization goals.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Laser-based three-dimensional manufacturing technologies for rechargeable batteries

Laser three-dimensional (3D) manufacturing technologies have gained substantial attention to fabricate 3D structured electrochemical rechargeable batteries. Laser 3D manufacturing techniques offer excellent 3D microstructure controllability, good design flexibility, process simplicity, and high energy and cost efficiencies, which are beneficial for rechargeable battery cell manufacturing. In this review, notable progress in development of the rechargeable battery cells via laser 3D manufacturing techniques is introduced and discussed. The basic concepts and remarkable achievements of four representative laser 3D manufacturing techniques such as selective laser sintering (or melting) techniques, direct laser writing for graphene-based electrodes, laser-induced forward transfer technique and laser ablation subtractive manufacturing are highlighted. Finally, major challenges and prospects of the laser 3D manufacturing technologies for battery cell manufacturing will be provided.

25 ENERGY STORAGE↗
DOE OSTI2022

Review of Computer-Aided Manufacturing (CAM) strategies for hybrid directed energy deposition

Hybrid additive manufacturing intertwines both additive and subtractive manufacturing layer by layer to digitally fabricate parts with complex geometries, improved surface finish and tight dimensional accuracies, the sum of which is difficult to obtain with any single process. Computer-Aided Manufacturing (CAM) software is required to orchestrate the machine toolpathing for both the deposition as well as the machining processes and is crucial for the successful fabrication of high quality structures. Additionally, CAM requires substantial operator input to account for challenging aspects of each fabricated structure. For example, deciding at which layer of deposition will the machining process continue to maintain access to complex cavities for finishing - internal features that would otherwise be unfinishable due to reach limitations or obstructions. Moreover, of the many commercially-available hybrid systems, each has a unique kinematic environment which can benefit from specific optimization of toolpath planning and substantial research has directly correlated toolpathing with the microstructure evolution, mechanical properties, porosity and residual stress state of the final fabricated part. This review explores the available strategies for CAM in the context of hybrid direct energy deposition, discusses the advantages and disadvantages of each and considers future CAM trends for this transformational digital manufacturing technology.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Virtual Inspection of Advanced Manufacturing via Process-Scale Digital Twins (Abbreviated Report)

Inspection and certification comprise the most significant bottlenecks in advanced manufacturing for NNSA applications, often requiring far more time and resources than the fabrication of the parts themselves. Traditional methods, such as manual review and X-ray computed tomography, are not only slow and costly, but also struggle to provide a clear connection between manufacturing instructions and the final performance of critical components. This gap limits both the agility and assurance needed to support the modernization and safety of the United States nuclear stockpile. In response, our Strategic Initiative established a digital twin framework that integrates realtime process monitoring, automated data analysis, and immersive virtual reality collaboration into a unified inspection pipeline. By leveraging data from sensors, machine instructions, and imaging, we created high-fidelity virtual models of manufactured parts that could be rapidly analyzed and certified. This approach was first demonstrated with Direct Ink Write, and then extended to other manufacturing settings, including conventional (or “subtractive”) manufacturing and to predict the end of life performance of parts per the aging and lifetimes programs. The result is a transformational capability: inspection times have been reduced by a factor of 120,000 without loss of accuracy and while simultaneously improving traceability and confidence in part quality. This framework not only streamlines certification for critical applications, but also positions the national security enterprise to respond more flexibly to emerging challenges, supporting agile manufacturing and digital engineering practices across a broad range of mission-relevant domains.

42 ENGINEERING↗
DOE OSTI2021

Iterative hybrid manufacture of a titanium alloy component

Here, this paper describes an iterative hybrid (additive + subtractive) manufacturing approach for a titanium alloy (Ti6Al4V) part using a laser hotwire directed energy deposition system (LHWDED) and a traditional four-axis milling machine tool. The term iterative hybrid manufacturing is used to described hybrid manufacturing where the additive and subtractive operations occur in multiple stages rather than sequentially. It is currently common to produce an entire part by sequential hybrid manufacturing by additively manufacturing (AM) an entire preform geometry that then requires post processing by another machine tool to create final part features. By contrast, a part produced by iterative hybrid manufacturing (IHM) does not produce the entire preform geometry in a single AM process. Instead, a portion of the entire preform geometry is manufactured by an AM process, then that portion is transferred to another machine tool which creates features in that portion, and then that machined portion is transferred back to the AM machine to complete another AM process. There is no limit to the number of iterations that an IHM process can have. IHM offers several advantages over sequential hybrid manufacturing such as the use of shorter and stiffer subtractive tooling, better access to part geometries that require subtractive processes, and the separation of the AM heat source from the subtractive machine tool. A titanium alloy demonstration part was successfully manufactured by IHM with three iterations using a shared pallet system between the AM machine tool and the subtractive machine tool.

Hybrid manufacturing↗
DOE OSTI2023

OPERATOR 4.0 FOR HYBRID MANUFACTURING

Hybrid manufacturing, a combination of additive and subtractive manufacturing capabilities in one system, has recently become a more viable production option across several industries. Although current hybrid manufacturing research covers a broad range of topics, there is a lack of focus on how this new technology impacts both the designer and the operator of hybrid systems. This paper identifies areas of literature across design theory and Industry/Operator 4.0 research efforts and presents a path for applying this research to hybrid manufacturing users. The unique relationship between operator and designer is highlighted as they learn new strategies and develop new intuitive judgements over time to become the first experienced/expert users of hybrid manufacturing. The potential impact of excessive cognitive workload due to the novel combination of processes is discussed. This paper begins a critical discussion about proper knowledge transfer to other hybrid designers and operators, as well as towards efforts of monitoring, inspecting, and automating hybrid manufacturing processes.

Fillingim, Blane↗
DOE OSTI2021

Investigation of interfacial structures for hybrid manufacturing

Hybrid manufacturing is a combination of additive and subtractive manufacturing in a single machine. Typically, planar substrate substrates are used for deposition and do not correspond to scenarios encountered in repair applications where the substrate can often be non-planar. Hybrid manufacturing opens the possibility for repairs by leveraging the five-axis mill to prepare the substrate for deposition. However, as the substrate geometry changes, so does the associated heat transfer during deposition and subsequent microstructures. This paper focuses on understanding the changes in microstructure and material properties with changing substrate geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Advanced and functional composite materials via additive manufacturing: Trends and perspectives

Additive manufacturing (AM) has many advantages over conventional subtractive manufacturing methods. The cost-effective AM allows for precise fabrication of complex structures with less material waste, making it a popular manufacturing process in many applications. The recent development of AM materials has advanced significantly. Further, by precisely controlling material distribution and microstructural features, AM facilitates the creation of new composites with specific requirements. AM techniques have contributed considerably to integrating unique functionalities for various applications. This review emphasizes multiple categories of materials, including metal alloys, polymer-based composites, and sustainable composites, as well as applications of sensing materials and strategies and emerging artificial intelligence and machine learning.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Neutron detection efficiency measurements of organic glass scintillator arrays

We characterize the neutron detection efficiency of pixelated organic glass scintillator (OGS) arrays manufactured in two ways: an additive method in which the OGS is cast in place in a pixelated mold, and a subtractive method in which the scintillator is first cast as a large block before being cut in bars and bonded together to form the array. The cast-in-place array utilizes a mixture of “bis(9,9-dimethyl-9H-fluoren-2-yl)diphenylsilane” (P2), “tri([1,1'-biphenyl]-4-yl)(phenyl)silane” (PB3), and “4-bis(2-methylstyryl)benzene” (MSB), and 50% by weight of polystyrene is added to the mixture for subtractive manufactured array. We compare the performance of the OGS arrays to that of an EJ-299-33M plastic scintillator array that was manufactured using a subtractive process similar to that of the second OGS array.

Neutron detectors (cold, thermal, fast neutrons)↗
DOE OSTI2022

Coolant Channel Design for Additively Manufactured Reactor Cores

Additive manufacturing (AM) methods are currently being explored for applications in nuclear reactors to make advanced reactors more efficient, safe, and reliable. The Transformational Challenge Reactor (TCR) program has explored AM for nuclear by designing a high-temperature gas reactor (HTGR) using an AM silicon carbide fuel form with uranium nitride–tristructural isotropic fuel. In this study, we detail the design process for the TCR fuel form’s coolant channels using computational fluid dynamics models with conjugate heat transfer. Additionally, this work discusses how these models were interfaced with other design teams, project milestones, and the agile design method used to mature the reactor design. The methodology deployed was able to create a channel design with lower maximum fuel temperatures and thermal stresses in the fuel form over traditional channel designs that can be manufactured subtractively. These results were achieved with only small manufacturing penalties. Results are discussed and presented on lessons learned for designing AM components for nuclear reactors. Finally, areas of opportunity are discussed for advanced design tools to further automate design activities and optimize reactors with fewer built-in assumptions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗