Multi-material Capabilities and Process Development in Hybrid Manufacturing

A new hybrid system using Liquid Metal Jetting (LMJ) and Laser Directed Energy Deposition (LDED) combines two additive manufacturing technologies with subtractive technologies creating a new manufacturing capability enabling complex multi-material parts and part repairs. With the addition of LMJ to the system, millimeter features can be realized for high resolution requirements and internal cavities where subtractive machining is not possible. For larger and less stringent part features, LDED can be utilized thereby maximizing productivity and part complexity. For high tolerance surfaces, CNC machining can be used for the best of all worlds.

The system also supports the use of multiple materials within both LMJ and LDED, offering a significant advantage for advanced manufacturing. One of the key challenges in multi-material hybrid manufacturing is ensuring strong interfacial bonding between dissimilar materials. This presentation will delve into the process recipe development required to achieve optimized bonding and will present data from a case study involving dissimilar materials, demonstrating the potential of this hybrid approach for future applications.