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The purpose of this paper is to present a new method for automated post machining process planning for a hybrid manufacturing process. The manufacturing process is expected to generate complex functional parts by taking advantage of free form surface creation from additive manufacturing and high-quality surface finishing from CNC milling.

The hybrid process starts with additive manufacturing to generate a near net shape part with pre-defined machining allowances on surfaces requiring high quality surface or tight tolerances, along with integrated fixture geometry. The next step is to conduct automated machining process planning to determine critical parameters such as setup angle, tool selection, depth, tool containment, and consequently, the NC code to machine the part.

This method is shown to be a feasible solution for rapidly creating functional parts. The tests have been conducted to validate the method developed in this paper.

This paper introduces a new automated post machining process planning method for integrating additive manufacturing with a rapid milling process.

This study aims to introduce a new method for locating candidate substrates in part models and evaluating their feasibility.

Slices of an STL model along candidate directions are evaluated for the fitting of regular cylindrical and rectangular stock. Next, the part model is skeletonized and tested for collision assuming deposition growth of features from the candidate substrate.

The method is successfully able to find feasible substrates and conduct collision simulation for a variety of part models.

The algorithm is limited to cylindrical and rectangular substrates and only considers collision between the substrate and the deposition head.

This method represents a new approach to solving a portion of the hybrid manufacturing process planning problem.