3D printing for ultra-precision machining: current status, opportunities, and future perspectives

doi:10.1007/s11465-024-0792-4

Front. Mech. Eng.

2024, Vol. 19

Issue (4) : 23 https://doi.org/10.1007/s11465-024-0792-4

3D printing for ultra-precision machining: current status, opportunities, and future perspectives

Tao HE¹, Wai Sze YIP¹(

), Edward Hengzhou YAN¹, Jiuxing TANG¹, Muhammad REHAN¹, Long TENG², Chi Ho WONG³, Linhe SUN¹, Baolong ZHANG¹, Feng GUO¹, Shaohe ZHANG⁴, Suet TO¹(

)

¹. State Key Laboratory of Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong, China
². Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong, China
³. Department of Physics, The Hong Kong University of Science and Technology, Hong Kong, China
⁴. School of Geosciences and Info-Physics, Central South University, Changsha 410083, China

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Abstract

Additive manufacturing, particularly 3D printing, has revolutionized the manufacturing industry by allowing the production of complex and intricate parts at a lower cost and with greater efficiency. However, 3D-printed parts frequently require post-processing or integration with other machining technologies to achieve the desired surface finish, accuracy, and mechanical properties. Ultra-precision machining (UPM) is a potential machining technology that addresses these challenges by enabling high surface quality, accuracy, and repeatability in 3D-printed components. This study provides an overview of the current state of UPM for 3D printing, including the current UPM and 3D printing stages, and the application of UPM to 3D printing. Following the presentation of current stage perspectives, this study presents a detailed discussion of the benefits of combining UPM with 3D printing and the opportunities for leveraging UPM on 3D printing or supporting each other. In particular, future opportunities focus on cutting tools manufactured via 3D printing for UPM, UPM of 3D-printed components for real-world applications, and post-machining of 3D-printed components. Finally, future prospects for integrating the two advanced manufacturing technologies into potential industries are discussed. This study concludes that UPM is a promising technology for 3D-printed components, exhibiting the potential to improve the functionality and performance of 3D-printed products in various applications. It also discusses how UPM and 3D printing can complement each other.

Keywords ultra-precision machining 3D printing additive manufacturing future perspectives start-of-the-art-review

Corresponding Author(s): Wai Sze YIP,Suet TO

Issue Date: 23 August 2024

Cite this article:

Suet TO,Shaohe ZHANG,Feng GUO, et al. 3D printing for ultra-precision machining: current status, opportunities, and future perspectives[J]. Front. Mech. Eng., 2024, 19(4): 23.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-024-0792-4
https://academic.hep.com.cn/fme/EN/Y2024/V19/I4/23

AM type	Materials	Definition	Advantages	Disadvantages
Selective laser sintering (SLS)Electron beam melting (EBM)	Paraffin, nylon, and metal materials, including aluminum alloys, cobalt-based materials, nickel-based alloys, stainless steel, titanium alloys, and their composites	An electron beam or laser is used to melt or fuse powder materials to produce components.	It can be used to efficiently print a wide range of materials and multiple parts simultaneously.	Equipment and material costs associated with this technique are high, and the density and surface roughness of the printed specimens are poor.


Laser-engineered net shaping (LENS)			It can manufacture and machine parts with complex curved surfaces without molds.	The printed specimen is prone to cracking due to high internal stress, and its surface accuracy is poor.

Selective heat sintering (SHS)			It eliminates the need for support structures and has low cost.	It takes a long time to print and exhibits poor accuracy.

Fused deposition modeling (FDM)	Polylactic acid, acrylic butadiene styrene, polypropylene, polyethylene, and other composites that contain ceramics or metals	Heating and extruding thermoplastic composites to print layers	It can print parts with complex structures and details and is suitable for small batch production due to low cost.	It has obvious print marks and is not suitable for printing large specimens.

Binder jettingInkjet powder printing	Polymers, metals, ceramics	Using jet chemical binder onto the spread powder toform a layer	It has a simple process, fast forming speed, and high precision printing for small specimens.	It prints samples with poor mechanical properties that require further post-processing.
	Polymers, metals, ceramics

Sheet lamination	Paper, plasticfiber composites	It creates objects by stacking multiple layers of foil that consist of thin sheets of materials on top of one another.

Stereolithography (SLA)	Photopolymer resin,polymers	It refers to the use of laser, light, or UV light to cure photoresponsive polymers.	It has high printing accuracy, a simple process, and a short production cycle. It is mostly used for optics and medical applications.	It has high equipment cost and generates toxic and polluting gases during printing.

Tab.1 Comparison of different AM techniques [47,84,85]

Fig.1 Current mainstream 3D printing technologies. The listed technologies are collected from Refs. [89–94]. The images quoted above have been rearranged and reprinted with permission.

Fig.2 Integration application of UPM and 3D printing for cutting tools. The listed case studies are from Refs. [103,109,111,117]. The images quoted above have been rearranged and reprinted with permission.

Fig.3 Combining UPM and 3D printing for mold insert fabrication. The listed case studies are from Ref. [125]. The images quoted above have been rearranged and reprinted with permission.

Fig.4 Combining UPM and 3D printing for optics. The listed case studies are from Refs. [133–136]. The images quoted above have been rearranged and reprinted with permission.

Fig.5 Integration application of UPM and 3D printing for machineries. The listed case studies are from Refs. [66,137–139]. The images quoted above have been rearranged and reprinted with permission.

Fig.6 Proposed hybrid UPM and 3D printing for microstructures fabrication.

Fig.7 Potential micro- or nanostructures for biomedical applications. The listed case studies are from Refs. [182,183]. The images quoted above have been rearranged and reprinted with permission.

Fig.8 Future perspectives of hybrid 3D printing and UPM.

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