Hybrid manufacturing is an innovative technology in production. But how can this method be applied to the processing of precious metals?
The processing of precious metals requires special expertise in order to meet the requirements and further develop the technology. For a long time, the casting of precious metals was the predominant method for series production. In the 21st century, additive manufacturing processes have opened up new perspectives that are also revolutionising precious metal technology. Hybrid manufacturing – the combination of additive manufacturing and subtractive methods – represents a new complementary manufacturing technology. In the following, we explain what exactly this means and what advantages it brings. In our next blog post, we will use an example to explain how hybrid manufacturing is already being used successfully at C.HAFNER.
Hybrid manufacturing: Additive and subtractive manufacturing processes in combination
In hybrid manufacturing, digital and analogue technologies merge into an efficient workflow, the best of two worlds becomes one: hybrid manufacturing is the seamless combination of metallic 3D printing as an additive process with classic machining processes such as turning and milling. C. HAFNER is already using this concept in the production of electrodes or watch parts, for example. The components/parts are 3D printed close to the final shape using the Laser-MetalFusion process and then machined using CNC technology. This highly automated production requires excellently equipped machinery and a great deal of expertise. Accordingly, the precious metal specialist is continuously expanding its capacities with various configurations of 3D printing systems as well as turning and milling centres. State-of-the-art measuring systems also ensure maximum precision and compliance with customer specifications – even in large series.
The advantages of hybrid manufacturing
Hybrid manufacturing combines the advantages of both additive and subtractive technologies. 3D printing enables new design options such as hollow bodies with an unusual volume in relation to their weight. Components, prototypes and design changes can be realised directly in metal in the shortest possible time. CNC post-processing increases efficiency in the machining process and delivers the usual high precision and surface quality.
Efficient production
In addition, the production of near-net-shape additively manufactured semi-finished products requires significantly less material and generates a lower processing volume and volume of cutting stock compared to conventional processes. Due to the high quality of the precious metal powder from our own production, the powder that is not used in the production process can be reused in the next process without further processing and without having to go through an energy- and resource-intensive recycling process beforehand. Scrap material is only produced by machining in the CNC process – although the dimensions of the additively manufactured semi-finished product are significantly lower compared to conventional semi-finished products.
The advantages are stable quality in industrial series production thanks to lean automated processes and increased efficiency and flexibility. Component production as a service by C.HAFNER minimises the costs associated with precious metals in the customer’s own production processes and capital commitment.
Environmentally friendly processes
The production of near-net-shape additively manufactured semi-finished products requires less material than conventional processes. This also results in less waste material compared to the processing of conventional semi-finished products. Hybrid manufacturing therefore not only reduces the amount of material used, but also the amount of material waste and ultimately minimises the ecological footprint of the entire production process. A study by the INEC Institute at Pforzheim University shows that the product carbon footprint of hybrid-manufactured components is significantly lower than that of conventional process chains, which include primary moulding, forming and machining. Hybrid production in precious metals therefore represents an environmentally friendly approach that offers both ecological and economic benefits. Read more in our blog post: „CO2 footprint comparison: conventional and additive manufacturing with precious metals.“
Conclusion
Hybrid production in precious metal marks a milestone in series production. The seamless combination of additive and subtractive manufacturing processes opens up new design possibilities and simultaneously enables efficient production processes.
C.HAFNER, as a leading player in this field, is continuously investing in state-of-the-art technologies and expanding its capacities to ensure maximum precision and quality in large series. Hybrid manufacturing minimises material and capital expenditure, reduces the carbon footprint and offers customers an economical and ecological solution. This innovative approach is redefining the boundaries of component manufacturing and paving the way for a sustainable and progressive future.