The document presents various projects related to tooling applications and hybrid processes in additive manufacturing, detailing objectives, progress, and outcomes for each initiative. Key projects include conformal cooling for high pressure die casting, an advanced modular platform for faster production, and digital hybrid units aimed at improving repair methods. The emphasis is on collaboration, commercial viability, and the integration of new technologies to enhance efficiency and reduce costs in manufacturing.

1. Topic
7:
Tooling
applications
&
Hybrid
Processes
Presenting
Stephen
Fitzpatrick
Rhys
Jones
Martin
Chisholm
Alex
Josifovic
Stuart
Christie

2. DigiTool Overview
©2018
AFRC,
University
of
Strathclyde
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Stephen Fitzpatrick-­ AFRC Machining and AM Group
Lead
Additive International
10th July
2018
Awaiting
approval
of
slides
Project
ref
103755

3. Topic
7:
Tooling
applications
&
Hybrid
Processes
Pitches

4. Project
title:
AM
For
HPDC
Abstract:
How
do
we
best
produce
conformal
cooled
components
to
deal
with
the
demands
of
the
High
Pressure
Die
Casting
process?
Presenter
name/
company:
Rhys
Jones,
CastAlum
Project
ref
104037

5. Project
Objectives
Your
requests
to
UK
Research
(Universities,
UKRI)How
does
this
contribute
to
delivering
the
AM-­‐UK
Strategy?
Progress/
Learning/
Outcomes
• Traditional
Cooling
Tubes
• Our
aim
is
to
produce
a
‘Rule
Book’
outlining
the
best
set
of
parameters
for
the
HPDC
process
• Develop
Simulation
Packages
• Conformal
Cooling
Tubes
• Coal
Face
• Simulations
• Building
Project
ref
104037

6. Project
title:
Advanced
Modular
Additive
Manufacturing
Platform
Abstract:
A
novel
AM
build
process
consisting
of
separate
modules
to
facilitate
control
of
individual
parameters,
at
speed.
Presenter:
Martin
Chisholm
-­‐ Lead
Project
Manager-­‐ Freeform
Fabrication
Industries
Ltd
Collaborative
Team:
Project
ref
103455

7. • SME
– Simpler
Access
to
Resources
• Commercial
Interests
vs Publishing
• “Productionizing”
AM
vs ‘Hi
Tech
Hi
Cost’
Project
Objectives
Your
requests
to
UK
Research
(Universities,
UKRI)How
does
this
contribute
to
delivering
the
AM-­‐UK
Strategy?
Progress/
Learning/
Outcomes
To
“Bridge
the
Gap”
from
prototype
mould
tools
to
low
cost
production
tooling
• Excellent
Progress
towards
Our
End
Goal
• Perseverance
key
to
Success
• Keep
Communicating
&
Keep
it
Simple
• Commercial
Needs
Paramount
-­‐ Bringing
Senior
Management
‘along’
• On
Course
To
Prove
AM
Produced
Tooling
at
Volume
with
Reduced
Cost
&
Lead
Time
• Positive
Disruption
to
Supply
Chains
• Re-­‐shoring
UK
Manufacturing
• Digitised
Manufacturing
(Data
– Tool)
Project
ref
103455

8. Project
title:
CONnected Flexible
dIGital hybrid
additive
manufacturing
Unit
designed
for
REpair (CONFIGURE)
Abstract:
Current
repair
methods
are
often
based
on
a
series
of
complex
manual
operations.
To
control
and
ensure
that
the
high
performance
parts
have
the
required
level
of
integrity
is
a
challenge.
Using
the
CONFIGURE
approach
has
potential
to
save
up
to
£1m
pa
by
reworking
of
defective
mining
and
rail
components
and
reduce
the
risk
of
substantial
financial
penalties
through
interruptions
to
major
mining
and
rail
operations.
In
addition
to
using
advanced
materials
automated
repair
solutions
will
minimise
manual
repair
operations
which
expose
workers
to
hazards
including;
noise,
fumes
and
vibration,
all
which
have
serious
long-­‐term
health
implications.
Presenter
name/
company:
Alex
Josifovic
/
Weir
group
plc.
Awaiting
approval
of
slides
Project
ref
103459

9. Combined
Laser
Additive
Manufacturing
and
Subtractive
Surface
Finishing
(CLASS)
Project
innovation
lies
in
the
ability
to
build
larger
parts
with
minimised residual
stress,
and
to
integrate
subtractive
laser
machining
and
surface
texturing
steps
during
the
AM
build
process.
The
project
is
also
making
real-­‐time
insights
into
build
performance
from
sensors
enabling
rapid
and
cost
effective
quality
assurance
required
in
regulated
parts.
Dr
Stuart
Christie
/
Renishaw
Project
ref
103458

10. Project
Objectives
Your
requests
to
UK
Research
(Universities,
UKRI)How
does
this
contribute
to
delivering
the
AM-­‐UK
Strategy?
Progress/
Learning/
Outcomes
• Scalable
AM
machine
platform
• Reduction
of
residual
stresses
• In
process
non-­‐contact
finishing
during
build
• Multiple
machines
globally
connected
and
monitored
via
sensors
for
real-­‐time
insights
• Many
facets
of
work
on
platform
size
• Integration
of
pulse
lasers
into
latest
platforms
• New
scan
strategies
• End
use
cases
covering
medical
(animal
and
human)
and
aerospace
• Team
working
superb
enabling
rapid
progress
• New
product
delivery
– scalable
architecture
• Productivity
/cost
– less
finishing
• Digital
connectivity,
process
feedback
and
control
• Continued
AM
funding
(Drama
isn’t
the
end)
• Removal
of
50%
over
whole
project
rule
• Allow
(insist
on)
funding
of
PhD
students
• Join
things
up
Project
ref
103458