Towards a methodology for integrated freeform manufacturing systems development with a control systems emphasis

A variety of fully integrated Freeform Fabrication (FFF) systems have been developed, a selected group for research and several for commercialization. The design methodology behind most of them is not documented, standardized, or rational. It is important to understand that the final product from any integrated system is affected not only by the unit manufacturing processes themselves, but also by the extent the individual units are assimilated into an integrated process. Thus, a scheme consisting of eight steps and the salient five elements necessary to create or retrofit an existing system to achieve an Integrated Freeform Manufacturing System (IFFMS) is proposed in this thesis. Specifically, mass-change, deformation and consolidation unit manufacturing processes are emphasized, as the priority is focused on rapid prototyping (RP) technologies. To illustrate the proposed scheme, the University of Missouri-Rolla (UMR) Laser Aided Manufacturing Process (LAMP) system is presented. Subsequently, the automated control system framework for a hybrid laser metal deposition system consisting of five phases is presented. The groundwork for an automated control system involves the integration of software with a real time controller, sensors and actuators. Key control parameters for a laser metal deposition process are reviewed and their incorporation into the software is correlated to the goal of an automated hybrid system. The first phase of the framework was completed and the results are presented in the second paper. Further development of the framework phases is elucidated and the future work for the control system implementation is provided.

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