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Department of Industrial and Systems Engineering College of Engineering

Hybrid Manufacturing:

Combining subtractive and additive manufacturing into a
one-workpiece operation

iMED first removes surface defects using computer numerical control (CNC) mills, then uses directed energy deposition (DED) to adhere powder or wire to reconstruct the surface.
Our focus is on linking process parameters with microstructural properties.

A 5-axis CNC mill has been retrofitted with an AMBIT Flex^TM system to enable both powder and wire additive manufacturing.

iMED investigates melting and solidification challenges in dissimilar 3D-printed metal materials for biomedical and aerospace applications. This work integrates materials science, mechanochemistry, and hybrid manufacturing techniques to better understand microstructural evolution, interfacial bonding, and defect formation during deposition.

Hybrid manufacturing enables material addition and removal in a single tool setup, saving both time and material in manufacturing and repair operations. Melting and cooling during the metal deposition process, however, can yield undesirable part properties including residual stress, porosity, weak interfaces, and poor surface quality. Our group is investigating process parameters for hybrid laser deposition to maximize strength, tailor surface roughness, and minimize defects in the final part.