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Procedia Manufacturing 00 (2019) 000–000
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Procedia Manufacturing 00
00 (2019)
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Procedia Manufacturing 00 (2019) 000–000
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Procedia Manufacturing 34 (2019) 738–746
Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia

47thSME
47th SME North American
AmericanManufacturing Research Conference, NAMRC
Penn47, Pennsylvania, USA
47th SME North
North American Manufacturing
Manufacturing Research
Research Conference,
Conference, NAMRC 47,State Behrend Erie,
Pennsylvania, USA
47th SME North American Manufacturing Research Conference, NAMRC 47, Pennsylvania, USA
Pennsylvania, 2019
Implementation
Implementation of hybrid additive manufacturing based on extrusion of
Implementation of of hybrid additive
additive manufacturing
hybridfeedstock manufacturing
and milling
based
based on
on extrusion
extrusion of
of
feedstock
Manufacturing Engineering Society and
International
feedstock milling
Conference
and milling
2017, MESIC 2017, 28-30 June
2017, Vigo (Pontevedra), Spain
Paolo Parenti*, Salvatore Cataldo, Alberto Grigis, Marco Covelli, Massimiliano Annoni
Paolo
Paolo Parenti*,
Parenti*, Salvatore
Salvatore Cataldo,
Cataldo, Alberto
Alberto Grigis,
Grigis, Marco
Marco Covelli,
Covelli, Massimiliano
Massimiliano Annoni
Annoni
Costing models*Corresponding
for didicapacity
Politecnico
Politecnico Milano,
Milano,
Politecnico di Milano,
a

author.Department
a
Department
a optimization
of
of Mechanical
Mechanical Engineering,
Tel.: +39-02-2399-8530; Engineering, inpaolo.parenti@polimi.it
Via
Via
E-mail address: La Industry
La Masa
Masa 1,
1, 20156, Italy4.0: Trade-off
Politecnico di Milano, Department of Mechanical Engineering, Via La Masa 1, 20156, Italy
20156, Italy
author.Department of Mechanical Engineering, Viapaolo.parenti@polimi.it
La Masa 1, 20156, Italy
a
*Corresponding Tel.: +39-02-2399-8530;
+39-02-2399-8530; E-mail address:
address:
between usedauthor.
*Corresponding
*Corresponding capacity
author. Tel.:
and E-mail
Tel.: +39-02-2399-8530; operational
E-mail
efficiency
paolo.parenti@polimi.it
address: paolo.parenti@polimi.it

Abstract
Abstract
Abstract
Abstract A. Santana , P. Afonso , A. Zanin , R. Wernke
a a,* b b
In the current industry, fabrication of metallic and ceramic artifacts by means of feedstock extrusion additive manufacturing is receiving attention
In
In the current
the current industry, fabrication of metallic and ceramic artifacts by means of feedstock extrusion additive manufacturing
manufacturing is is receiving attention
because
In of theindustry,
the current capacityfabrication of metallic
of this technology and ceramic
to deal
aand with lowartifacts
costs andby means ofthat
materials feedstock
possessextrusion additive
a low Additive Manufacturability
manufacturing isIndex
receiving
when attention
treated
because
because of theindustry,
of the capacityfabrication
capacity of this
of
of metallic
this technology
technology to deal
to deal ceramic
University
with
with lowofartifacts
low Minho,
costs
costs andby
and
means of
4800-058
materials
materials
feedstock
that
that possessextrusion
Guimarães,
possess Portugal
a low
a
additive
low Additive
Additive Manufacturability
Manufacturability
receiving
Index
Index when
when
attention
treated
treated
with high
because power beam
of the capacity technologies.
of this technology However, the
to dealthe
with extrusion additive
low costsadditive manufacturing
and materials lacks
that possess in
a low achievable accuracy
Additive Manufacturabilityand productivity
Index when therefore
treated
with
with high
high power
power beam
beam technologies.
technologies. However,
However,
b
Unochapecó,
the extrusion
extrusion 89809-000
additive Chapecó,
manufacturing
manufacturing SC,lacks
Brazil
lacks in achievable
inthis
achievable accuracy
accuracy and
andonproductivity
productivity therefore
therefore
techniques
with high powerthat can improve
beam the overall
technologies. performances
However, are
the extrusionrequired to
additive increase the impact
manufacturing that
lacks technology can have industry. This paper
techniques
techniques that can
that can improve
improve the overall
the overall performances
performances are required
are required to increase
to increase the impact
the impact thatinthis
that
achievable
this technology
technology
accuracy
can have
can haveandonproductivity
on industry. This
industry.
therefore
This paper
paper
demonstrates
techniques that how extrusion additive
can improveadditive
the overalltechnology of
performances metals and
are and ceramics can
required to increase be enhanced by
the impactbythatintegrating green-state
this technology milling
canmilling into
have oninto the
industry.manufacturing
This paper
demonstrates
demonstrates how
how extrusion
extrusion additive technology
technology of
of metals
metals and ceramics
ceramics can
can be
be enhanced
enhanced integrating
bygreen-state
integratingpartgreen-state
green-state milling into the
the manufacturing
manufacturing
cycle. In
demonstrates the hybrid cycle,
how extrusion the additive
additive and subtractive
technology of metals processes act
and ceramics alternatively on
can be enhanced the to shape its near-net form. This work
cycle. In
cycle. In the
the hybrid
hybrid cycle, the
cycle, the additive
additive and subtractive
and subtractive processes
processes act alternatively
act alternatively on thebygreen-state
on the integratingpart
green-state green-state
part shapemilling
to shape
to
into the
its near-net
its near-net manufacturing
form.
form. This work
This work
shows
cycle. Inhow this
thethis innovative method,
hybrid cycle, method, that
the additive integrates cutting
and subtractive and micro-cutting
processes operations
act alternatively on the
on thethe feedstock,
green-state part allows compensating
to shape its near-net the lack of accuracy
form.ofThis work
Abstract
shows
shows
and
how
micro this innovative
how reachability
innovative thatmethod, that
that integrates
characterize integrates
the
cutting
cutting and
extrusion-based and micro-cutting
micro-cutting
additive
operations
operations on
manufacturing on the feedstock,
method. feedstock,
In the
allows
allows compensating
compensating
manuscript, the
the
the lack
promising lack of accuracy
aspectsaccuracy
of the
shows
and microhow reachability
micro this innovative thatmethod, that integrates
characterize cutting and micro-cutting
the extrusion-based
extrusion-based operations on
additive manufacturing
manufacturing the feedstock,
method. In the allows compensating
the manuscript,
manuscript, the lack
the promising
promising of accuracy
aspects of the
the
and
hybrid reachability
concept are that
presented characterize
and discussed.the Some examples additive
of manufactured parts aremethod.
illustratedIn showing how the
complex geometries,aspects
with of
good
and micro
hybrid reachability
concept are that characterize the Some
extrusion-based additive manufacturing method. In showing
the manuscript, the promising aspects ofgood
the
Under
hybrid
surface the
concept
quality are presented
concept
can presented
be of
addressed
and discussed.
"Industry
and discussed.
with higher4.0",
Some examples
production
examples
production
of
of manufactured
processes
manufactured
flexibility. The
parts
will
parts
developed
are
be
are
hybrid
illustrated
pushed
illustrated
machine to
showingbe
prototype
how
how complex
increasingly
complex
adopted for
geometries,
geometries,
that scope is
with
interconnected,
with good
described
hybrid
surfaceconcept are presented
quality can
can be addressed
addressedandwith
discussed.
higher Some examples
production of manufactured
flexibility. The developedpartshybrid
developed are illustrated
machineshowing
prototype how complex
adopted geometries,
for that
that scope is iswith good
described
surface
informationquality based be onparts
a real with
time higher production
basis and, flexibility.
necessarily, The hybrid machine prototype adopted for scope described
along with
surface
along
the AISI316L
quality
with can be addressed that arehigher
with obtained by depositing,
production flexibility. Themuch
green-state morehybrid
milling,
developed efficient.
debinding
machineandInsintering
this context,
prototype the capacity
feedstock.
adopted Another
for that scopeoptimization
contribution
is described
along
is with the
provided the AISI316L
AISI316L
regarding
parts
parts that
the feedstockthat are
are obtained
obtained by
machinability
depositing,
bythat
depositing, green-state
is studiedgreen-state
milling,
milling,
under different
debinding
debinding
cutting
and
and sintering
conditions. sintering the
the feedstock.
The feasibilityfeedstock. Another
Another
ofprofitability
the hybrid
contribution
contribution
implementation
goes
along beyond
with
is provided
is
the
provided regarding the traditional
AISI316L
regarding the parts
the feedstock aim
that are of capacity
obtained
feedstock machinability by
machinability that maximization,
depositing,
that is
is studied green-state
studied under contributing
milling,
under different also
debinding
different cutting for
cutting conditions.andorganization’s
conditions. Thesintering the
The feasibilityfeedstock.
feasibility of
of the Another
the hybrid and value.
contribution
hybrid implementation
implementation
is provided
is confirmedregarding
and future thesteps to improve
feedstock the process
machinability thatare
is discussed.
studied under different cutting conditions. The feasibilityoptimization
of the hybrid implementation
Indeed,
is confirmed lean
and management
future steps to and
improve continuous
the process
is confirmed and future steps to improve the process are discussed. are improvement
discussed. approaches suggest capacity instead of
is confirmed and future steps to improve the process are discussed.
maximization.
© The study of capacity optimization and costing models is an important research topic that deserves
©© 2019
2019The
2019 TheAuthors.
The Authors.
Authors.
Published
Published
Published
by Elsevier
by Elsevier B.V. B.V.
©
©
2019
This
2019
The
contributions
This isisan
an
TheopenAuthors.
open from
access
access
Authors.
Published
both
article
Published theby
under
article by
Elsevier
bypractical
Elsevier
the CC
under the
Elsevier
B.V.
B.V.
and
BY-NC-ND
CC
B.V. theoretical
BY-NC-ND perspectives.
licenselicense This paper presents and discusses a mathematical
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
This is
This is an
an open
open access
access article
article under
under the
the CCCC BY-NC-ND
BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/)
license (http://creativecommons.org/licenses/by-nc-nd/3.0/)
Peer-review
model for
Peer-reviewunder
This is an openunder
capacity
under responsibility
access management
responsibility
article underof the
the Scientific
based
of Scientific onCommittee
the Scientific
CC BY-NC-ND different
Committee
licenseof NAMRI/SME.
costing models
of NAMRI/SME. (ABC and TDABC). A generic model has been
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
Peer-review
Peer-review under responsibility
responsibility of of the
the Scientific Committee
Committee of of NAMRI/SME.
NAMRI/SME.
developed
Peer-review under and itresponsibility
was used toofanalyze idleCommittee
the Scientific capacity of and to design strategies towards the maximization of organization’s
NAMRI/SME.
Keywords: Hybrid Manufacturing, Additive Manufacturing, feedstock, AISI316, Metal Injection Molding, Shape Deposition Manufacturing, milling, green-state
value. The
Keywords:
Keywords:
machining trade-off
Hybrid
Hybrid capacity
Manufacturing,
Manufacturing, maximization
Additive
Additive Manufacturing, vs operational
Manufacturing, feedstock,
feedstock, AISI316, efficiency
AISI316, Metal
Metal is highlighted
Injection Molding,
Injection Molding, and Manufacturing,
Shape Deposition
Shape Deposition it is shownmilling,
Manufacturing, that capacity
milling, green-state
green-state
Keywords: Hybrid Manufacturing, Additive Manufacturing, feedstock, AISI316, Metal Injection Molding, Shape Deposition Manufacturing, milling, green-state
machining
optimization
machining
machining might hide operational inefficiency.
© 2017 The Authors. Published by Elsevier B.V.
1. Introduction
Peer-review underand State of theofArt
responsibility components, but
the scientific committee of the Manufacturing with a limited
Engineering complexity
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1.
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The development of Additive Manufacturing field enabled manufactured
part with the
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Keywords: of
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installed
combination on the
of machine
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manufacturing, of Moreover,
shaped part to be obtained in with
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shortest and
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installed on
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machine or or working
working together.
together. Many
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Moreover, highly complex
complex parts parts with
with external
external andand internal
internal
these techniques
installed consist
on the same in the integration
machine or workingof additiveManydirected features or high geometrical precisionwithand surfaceand quality can
1. Introduction
these
these techniques
techniques consist
consist in the
in the integration
integration oftogether.
of additive directed
additive
of
directed Moreover,
features or
features
highly
or high
high complex parts
geometrical
geometrical precision
precision
external
and
and surface quality
surface
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quality can
can
energytechniques
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(DED) in withintegration
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directed be produced.
features or high However,
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surface of this
quality can
energy
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deposition (DED)
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and are
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management in
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importance
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machine technologies in planning
technologyandthat
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enclosed
of the hybrid complexity
in theequipment
ofsometime
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laser-bed
in modern
laser-bed fusion
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fusion (SLS)systems.
(SLS) or wire
or wire Inwelding
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general, it is defined
technologies are
as
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unused andthat
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complexity
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measured
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laser-bed Hybrid
fusion manufacturing
(SLS) or wire is becoming
welding more popular
technologies are could exceed
planning and in that
the of ofthe
cost the two
hybrid independent
equipment additive
that sometime and
adopted
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[1].ways:
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manufacturing is becoming more popular could exceed that of the two independent additive and
in several
in industrial
adopted [1]. Hybrid tons
applications ofbecause
manufacturing ofis
production,
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The
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and
and
in
in industrial
industrial applications
applications because
because of its
of its capability
capability to
to leverage
leverage subtractive
subtractive systems.
systems. The
Theout fact that
factonthat the
the additive
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and subtractive
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the
in* advantages
Paulo Afonso.
industrial of both
Tel.:
applications processes.
+351 253 510
because AM
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the E-mail
the advantages
advantages of both
of both processes. AM AM allows
allows toto create
create complex
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psafonso@dps.uminho.pt
of both a poor surface
processes. AM allows quality. Subtractive
to create complex
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2351-9789 © 2017
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Elsevier B.V.
precision
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complex.
manufacturing, on the other hand, allows to realize precision planning and operating sequence more complex.
2351-9789 ©
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Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
B.V.
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license (http://creativecommons.org/licenses/by-nc-nd/3.0/)
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
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This is an open under
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(http://creativecommons.org/licenses/by-nc-nd/3.0/)
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under article under
responsibility CC BY-NC-ND
of the Scientific license
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NAMRI/SME.
10.1016/j.promfg.2019.06.230
This is an open
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under article under
responsibility of the Scientific
the CC BY-NC-ND license
Committee of (http://creativecommons.org/licenses/by-nc-nd/3.0/)
NAMRI/SME.
Peer-review under responsibility of the Scientific Committee of NAMRI/SME.
Peer-review under responsibility of the Scientific Committee of NAMRI/SME.
 Paolo Parenti et al. / Procedia Manufacturing 34 (2019) 738–746
2 Paolo Parenti / Procedia Manufacturing 00 (2019) 000–000
At the same time, industry is putting lots of interests in the
last period on binder-based technologies for additive
manufacturing of metals and ceramica, such as the extrusion
freeform fabrication EFF [2-3], thanks to their capacity of
dealing with many materials with cost savings and system
simplicity benefits [4-5]. There are systems now ready for the
market such as Desktop Metal Studio System+, Markforged
Metal X that can produce parts exploiting green-shaping
deposition through extrusion and parts sintering.
Not only steel, but the extrusion freeform fabrication (EFF)
can ideally be adopted with all the materials that are easy to
sinter, therefore copper, carbides and ceramics are among the
ones that can easily be treated with the EFF and not with the
high-power beam technologies [4-6]. EFF allows also the
production of multi-material objects. Laser or electron beams
additive techniques used to produce near net shape parts
through solidification of melted metal powder layers have
some disadvantages. First, the implementation of a power beam
has higher costs for set-up and maintenance and increased
safety problems must be addressed in comparison to EFF. The
beam technologies are also more sensible in respect to the
powder quality. Dust formation and aging or oxidizing
phenomena of the powder must be considered. At the time EFF
has some design limitations that mainly relate to the constraints
of debinding and sintering processes. Despite debinding and
sintering are probably the most challenging aspects of binder-
based AM technologies, the shaping deposition process can
alter the overall performance and product quality, and therefore
needs to be adequately controlled [7]. Tight connection
between sintering performances and deposition strategies could
exist, therefore the entire process chain must be studied when
good results are needed.
One key point of the EFF is that the adopted feedstock
material has many similarities with the Metal/Ceramic
Injection Molding (MIM/CIM) process and therefore most of
the knowledge about debinding and sintering is already
available in the proper markets, i.e. MIM/CIM parts
manufacturer or more in general, powder metallurgy specialists
[5].
Figure 1: Scheme of hybrid manufacturing involving EFF and milling [8]
739
Use and development of new binders that can reduce
debinding times, increase the sintered parts density as well as
the productivity of the overall cycle are in study both in
academia and big industrial companies.
Among the many, layer thickness is one of the critical
parameters for augmenting the productivity during the
deposition process, as in standard FDM (Fused Deposition
Modelling) of polymers, but its value is usually constrained by
the achievable density and overall surface quality of the parts,
which typically decreases when layer thickness increases.
Considering these premises, the process chain involving
green-state deposition through EFF could benefit from a hybrid
approach where milling process is integrated into the cycle [8].
The adoption of milling in EFF can improve the surface
quality (of both external and internal faces), the achievement
of thin/small geometrical features and the part dimensional
control (considering the shrinkage that the parts undergo during
the production cycle). Finally, thanks to the possibility to
onboard finish the green parts with milling and to the fact that
milling runs much faster than deposition [9-12], higher
extrusion deposition rates can be adopted by unaltering the
final part quality, thus increasing the overall production rate.
This paper shows the implementation of the hybrid concept
that involves extrusion freeform fabrication and milling. The
aim is to demonstrate the feasibility of the approach applied to
metallic feedstock.
A description of the hybrid machine prototype and the entire
process chain is given, followed by an in-depth discussion on
the parameters that affect the part quality. Then, green-state
milling is discussed along with examples of machined products
that are then sintered to generate final parts.
2. Hybrid process chain
The process chain that involves the EFF of ceramic and
metals, Fig. 1, starts from the feedstock production or
alternatively from commercial MIM/CIM material. The
feedstock is then processed by the extrusion machine that
deposits the first part layers on the worktable.
740 Paolo Parenti et al. / Procedia Manufacturing 34 (2019) 738–746
Paolo Parenti/ Procedia Manufacturing 00 (2019) 000–000
After some layers, as soon as enough consistency is
generated on the part, milling can enter the process to further
shape the geometry and surfaces. The presence on the same
machine of two heads for additive and subtractive
manufacturing allows easy implementation of alternated
depositions and milling passes which can be performed based
on the required features and geometrical specifications. This
capacity allows the obtaining of internal cavities with tight
tolerance specification or more in general, the increase of the
productivity for a defined accuracy target. At the same time,
milling can be applied in multiple moments of the process chain
to improve the accuracy of the green-part and therefore
improve the shrinkage compensation (which is done by
imposing a controlled part oversizing). Milling can also be
applied after the sintering operations to finish functional
surfaces, but in this case new working placements are needed.
After the part is shaped, the green body undergoes debinding
phases which consist in solvent and/or thermal debinding steps
depending on the binder type and the total binder volumetric
content. For example, water debinding cycle can be used to
remove, when present, the waxes constituents from the binder
while thermal cycle is typically needed to remove the
thermoplastic resin binder residues. One of the most important
steps with some feedstock material is to assure that binder does
not leave any carbon residues or other that may alter the final
part composition. At the same time, part design must deal with
wall thickness limitation to avoid troubles in the debinding
phase, whereas an extremely bulk part would require longer
debinding times. After debinding, the brown part is
characterized by augmented fragility so particular care must be
taken in moving the parts. Then, sintering operation allows the
part densifying of the component, the closure of voids and
microcavities and obtaining the final mechanical properties
required. In this last step, it is fundamental to take under control
Figure 2: Fishbone diagram of extrusion additive manufacturing of metallic/ceramic feedstock
3
the dimensional variation of the components especially in the
presence of bulk workpieces and tiny/slender microfeatures
because part distortion may alter the part quality.
Sintered parts must be sufficiently dense and have the
required mechanical resistance and it is worth to mention that
this latter point is not only affected by the geometry but also by
the adopted deposition strategies and achieved surface
finishing.
2.1. Extrusion deposition
Extrusion deposition quality depends upon several factors.
The driving parameters are illustrated in the fishbone diagram
of Fig.2. Stand-off/hatch distance, extrusion velocity, plate and
extruder temperatures are those that have the most influence on
the deposition quality. Once feedstock and nozzle diameter are
selected, experimental investigations can be conducted to find
the optimal working windows for those parameters.
There are leading requirements for the extrusion that first
consist in avoiding nozzle clogging. Adhesion between
subsequent layers must then be guaranteed (each layer must
attach to previous ones). No air voids should remain after part
sintering and therefore a complete infill must be assured in the
feedstock deposition phase. Extrusion parameters must also
guarantee a homogenous binder dispersion in the green part.
2.2. Green-state milling
Selection of the most proper cutting tool type and size is
required depending on the geometrical feature’s dimensions,
feedstock composition, heated bed adhesion properties and
machine characteristics. Use of coated cutting tools and cooling
air can be prescribed to avoid tool clogging due to material
adhesion and tool wear, in case of highly abrasive feedstock
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4 Paolo Parenti / Procedia Manufacturing 00 (2019) 000–000
like ceramic ones. Cutting forces and acceleration rates limit
the material removal obtainable in milling since the parts are
not adequately anchored to the depositing heated bed. Heated
bed material and temperature can be appropriately selected to
improve this limit. At the same time, the machine must be
capable of performing accurate interpolation trajectories at
high speed, especially in the case of smaller tools. Milling can
be prescribed for flattening or contouring irregular deposited
surfaces or in the presence of critical internal features to finish.
In this case, deposition and milling of pure binder component
can be used to foster the generation of good internal surface
finish. A machine implementation with double extrusion heads
is a good solution for that. At the same time, green machining
can be adopted with materials that show poor machinability at
the sintered state, e.g. ceramic.
Since green parts contain high volumetrically content of
binder and do not have particles links, they have lower
mechanical properties compared to the brown and sintered
parts. Therefore, there are advantages of green-state machining
that consist in less forces, less thermal stresses and
consequently less tool wear. Precise dimensions can be
obtained in terms of part shape together with good finished
surfaces (as reported in terms of roughness values in paragraph
4.3). Tools for green machining can be less expensive since
induced cutting stresses are lower. By controlling the cutting
process, it is also possible to obtain higher density packing after
sintering.
In green-state machining, chip removal mechanism differs
from the standard metal cutting where the tool induces plastic
deformations and slip planes for the chip formation. In green
machining different phenomena turns in action as the particle
displacements inertia, the viscous behavior of the binder and its
thermal softening and in some cases even the particles
fracturing [10,13].
The machinability of the green parts depends a lot on the
feedstock and binder characteristics. The binder type, its
mechanical strength and the quantity inside the powder define
the mechanical strength of the feedstock. With these, there are
other characteristics that play a role such as part porosity, grain
size, toughness, hardness and strength and also elastic and
thermal properties. Since these parameters are many, usually
experimental approaches are adopted to assess the green
machinability index of the material.
It must be considered that green machining can be used only
on components that have the necessary mechanical strength to
withstand the pressure action produced by the tool during the
operation. Clamping of the parts is also an important aspect,
especially when additive produced components cannot be
glued or fixed before cutting. The cutting process parameters
must be set in order to avoid cracks or breakage of the
components and keep low values of resultant cutting forces. A
proper parameter setting must also consider the obtainable
surface quality, since milling of green component can easily
lead to surface integrity defects affecting the upper edges and
the entrance and exit zones, especially when thin features are
machined.
741
Figure 3: Machine prototype developed in house
3. Materials and Method
3.1. Hybrid prototype
A machine prototype was developed in-house exploiting a
two-piston extruder that was designed specifically, starting
from an injection molding commercial product, Fig. 3.
A similar concept was developed by Lin et al. used in a
novel hybrid additive-manufacturing technique (HASM) with
the implementation of a six-DOF axis robot equipped with two
types of heads for extrusion and subtractive manufacturing
processes [14].
It is possible to feed the loader through a hopper, with
feedstock granules that are preheated by the resistors in the
plasticizing chamber. Once the input material is heated in the
plasticizer (or charger) for a few minutes, it is possible to
activate the piston that pushes the material through the
plasticization spheres (maximum piston stroke 77 mm) into
extrusion chamber. The volume of a full extruder charge is
9000 mm3 (14 mm in diameter) and it is pushed by the
extrusion piston towards the nozzle. Due to its bulkiness, the
extrusion head is rigidly connected to the ground while the
working plate is handled by a specific handling system.
Regarding the machine architecture, a Linear Delta with 3
translational degrees of freedom allows moving the working
plane in the x-y plane to deposit a layer and along the z-axis to
proceed in height. This reduces the size and complexity of the
final machine. It also avoids vibrations that occur during the
rapid change of direction due to the high inertia forces that
decrease the surface quality of the printed parts. This kind of
kinematics is chosen in order to improve rigidity, precision and
dynamics. The electric motors are controlled using a PID
system through three control loops (current, speed and
position). They move three sliders and give the desired
movement to the work plane. The maximum working area is
250x250 mm whereas the maximum printing area is 200x200
mm and the maximum printed weight is 8 kg, with maximum
available extrusion pressure of 22 MPa [15-16].
To allow the hybridization, a machining spindle that can
rotate faster than 10 krpm was installed close to the extruder
nozzle. It can move on a vertical slide to retract when not in use
and is controlled by a proper driver, commanded by a
potentiometer that is connected to the machine PLC and pulpit
control. It can fit tools as big as 10 mm in diameter. It is
certified to have low runout thus permitting the use of tiny tools
742 Paolo Parenti et al. / Procedia Manufacturing 34 (2019) 738–746
Paolo Parenti/ Procedia Manufacturing 00 (2019) 000–000 5

down to less than 0.5 mm, enabling microcutting operations 4. Green shaping processes
[17].
In the experiments, milling operations were carried out on 4.1. Extrusion deposition strategies and slicing software
both the hybrid prototype and an ultra-precise micromilling
machine (Kern Evo), with 2-flute carbide flat end milling tools According to the process chain, parts must be oversized due
(PVD coated, cutting edge radius of about 8 μm ranging from to the chip removal operations and the shrinkage occurring
0.5 mm to 6 mm in diameter, tested up to 100 m/min of cutting during debinding and sintering. Once the CAD drawing is
speed and in the range of 30%-100% of axial and radial properly scaled, an STL file is produced [1]. Being used for
immersions (i.e. depth of cuts divided by the tool diameters) in over 30 years with Fused Deposition Modelling printers, the
flattening and contouring modes. The feed per tooth was set in STL file format has become the Rapid Prototyping industry’s
the range of 5-40 μm. Air chilled at 5 °C was supplied to standard data transmission format.
refrigerate the cutting area and avoid chip accumulation. A critical point is the conversion from STL, obtained by
CAD, to ISO G-code file, done by software called slicer.
3.2. Feedstock preparation In this paragraph, the comparison between three different
well-known slicers is showed in order to select the best one
The feedstock adopted in all the experiments was produced based on their capacity of coping with metallic feedstock
in-house and was designed in terms of metal grain dimension, deposition with different geometries and structures.
binder type and binder volumetric content. The base material
tested consists in a commercial AISI316L powder (D50 = 8.8
μm, density = 7.9 g/cm3) produced by atomization by Sandvik
Osprey (UK). The adopted binder is a commercial water-
soluble material produced by eMBe (type Embemould K83)
with a density = 1.05 g/cm3. A 60 % volumetric percentage (92
% in weight), was adopted as typical in Metal Injection
Molding applications. A twin screws compounder (Brabender
2 mm
Plasti-Corder) was adopted for feedstock mixing, Fig.4.
Homogeneous feedstock was obtained by optimizing the
mixing time and mixing temperature in the range of 30 min and Figure 5: 3D image from 3D microscopy. (a) top surface; (b) lateral
surface
140 °C respectively. Pellets of ф2.5 mm x L10 mm were then
produced to feed the extrusion deposition process. Each software required different slicing parameters to
generate the deposition path. It must be considered that the
studied software have similar architectures and design but
define different deposition parameters and strategies. Since the
software require different setup and types of parameters for
running a cycle, the comparison is performed by considering
the best parameter set for each one.
Usually, parts are sliced in horizontal layers to generate
plane movements in x-y directions.
The different features and parameters that are required are
the shells perimeters that define the surface quality, the infill
Figure 4: Twin screw mixer used for feedstock preparation and DSC which represent the internal pattern used to fill up the part, the
analysis skirt/brim that are aimed at fostering the adhesion with the
DSC (Differential Scanning Calorimetry) analysis was used plate, the hatch distance which represents the distance between
for characterizing the melting points of the solely binder
constituents, affected by many factors such as binder
composition and not least by the presence of metal particles in
the feedstock. The DSC analysis shows that 3 main
components with a minimum melting point of about 63 °C and
a maximum melting point of about 118 °C are present in the
mixture, Fig.4. The extrusion temperature is varied between 90
°C and 140 °C and consists in the temperature of the mixing
chamber of the extruder. Nozzle and plasticizing piston
temperatures were always set equal to the extrusion
temperature.
Figure 6: Real specimens dimensions compared to the nominal ones
(red dashed lines).
6 Paolo
Paolo Parenti Parenti Manufacturing
/ Procedia et al. / Procedia Manufacturing
00 (2019) 000–000 34 (2019) 738–746 743

10 mm

Figure 8: Deposition strategy. (a) zig-zag 45°; (b) concentric.

obtained with each software (with nominal dimension: length

= 121 mm, height = 6 mm and
width = 9 mm) by empirically optimizing the deposition.
Quantitative comparison analysis was conducted on top and
lateral surface roughness and dimension, Fig.5-6, using 3D
microscopy (Alicona G4).
Moreover, qualitative analyses were conducted by
observing the visual aspect, the consistency and visible defects
of the samples, Fig.7, Table 1. Deviation from nominal
Figure 7: Slicing trajectory (without shell/perimeter) and specimens dimension was mainly due to different amount of extruded
produced with 3 different slicers
material and perimeter losses. Nine specimens were tested and
Table 1: Ranking of the achievable quality with the three slicers coded, Fig.7.
basing on three functions: absolute appearance, lateral surface Ideamaker revealed to be the best option to obtain a good
quality, top surface quality (I: Ideamaker, C: Cura, S: Slic3r). external quality of components. Cura was the most complete
and flexible software; it was possible to choose many different
Absolute Lateral surface Top surface options that can affect the final component and can help the
I2 I1 C1 final user in building complex and difficult 3D structures.
C3 I2 C3 Slic3r showed many criticalities in the specimen production
C1 C3 C2
giving high sensitivity to shell/perimeters breakage and voids
generation. All the slicers showed a tendency to generate wider
C2 C1 I2
and taller feedstock workpieces, Fig. 6, due to the plowed areas
I3 C2 I3 on the specimen’s surfaces. No systematic bias, however, was
I1 I3 I1 observed in length of the specimens but large dimension
S2 S3 S1 dispersion was observed among the replications for all the
S3 S1 S2
software. This variation, that could be associated with the
extrusion process variations in relation to feedstock
S1 S2 S3
characteristics, remained constant for all the three software
two deposited wires and the layer height which indicates the indicating a minor role of the slicing strategy.
vertical distance between each deposited layer. With slender pieces, where a dimension is predominant to
In addition, printing parameters must be set in order to another, cooling rate can be quicker than the deposition rate,
obtain the desired components. Feedstock temperature is therefore limiting the inter-adhesion property of the layers and
controlled by heating resistors inside the extrusion head. eventually causing layer cracking. Maximum distance between
Heated bed ensures a proper attachment of the first deposited adjacent points was found to be related with the deposition rate
layer. Plane movement speed and nozzle diameter should be a and the feedstock material used. Basing on this observation, the
trade-off between productivity, material adhesion and part most suitable infill method was found.
accuracy.
To test the influence of the slicer characteristics, a
comparison was run by empirically testing the three slicers to
obtain the best samples they could produce for a defined
geometry.
Each slicer has an optimal field in which the component
shows the best characteristics, so the best choice would be to
use different slicers for different products and features. The
choice was guided by the main open-source software used in
FDM production. Cura, Slic3r and Ideamaker were the three
software selected for the comparison.
The methodology consisted in the following step. Starting Figure 9: Infrared images taken during extrusion of cube samples
from dog-bone STL specimens (whereas the dog-bone shape 20x20x10 mm (taken with Flir T-Series thermal Imaging System)
was designed according to the Standard ASTM E8/E8M), G-
codes were created with the slicers. Three samples were
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Paolo Parenti/ Procedia Manufacturing 00 (2019) 000–000
Under slender workpiece conditions, a 45°(zig-zag) infill is
preferable to the standard 90° (concentric) method (Fig. 8). For
shapes close to circular form the two methodologies did not
reveal so much difference. Though, the 45° infill configuration
was selected because it could also provide an improvement of
the machinability of the parts, as explained in paragraph 4.2.
In a second extend, the extrusion temperature management
was found to be critical. The heated bed and extrusion
temperatures must be appropriately adjusted to have enough
fluidity to be able to print complex geometries. Then, the
deposition strategy must consider also some temperature
related variables as part geometry and component heat
capacity. The heated bed temperature was tuned by trial and
error testing with starting conditions that were selected based
on DSC analysis of the feedstock. Extrusion temperature
played also a role on the optimal bed temperature values. In the
tested cases, the adopted heated bed temperature was ranging
from 70-80 °C.
The use of an infrared camera was suitable in the carried out
tests for supporting the above setup of the temperature values.
Extrusion monitoring could be a viable way to keep under
control and understand the deposition of new layers upon the
already deposited ones that are colder. Indeed, thermal imaging
(Fig. 9) provides useful information detecting possible cold
spots and so probable cracks in those areas. In case the two
previous options revealed not to be enough, ad hoc deposition
strategies could be implemented by the slicing software and
infrared lamps could be properly activated to provide the
required heat. The preliminary testing of this monitoring
technique confirms that in-process monitoring can be
implemented but specific design of the measurement system
must be provided.
Moreover, thermal imaging could help in reducing the
overheating during milling process by allowing the adaptation
of cutting parameters to avoid binder segregation that could be
detrimental for the final part mechanical properties.
4.2. Deposition strategy selection for improving part
machinability
In general, milling must be adopted when specific finished
features are required, like slots with sharp edges, flat surfaces,
precise holes or complex free-form geometries with low
scallop heights. Since milling is much faster than extrusion, it
could be adopted to compensate rougher (but faster)
depositions, producing an overall increase of productivity and
accuracy.
However, process planning of extrusion and milling must be
done conjunctly by considering the two processes since there is
interaction between them.
Nowadays, there are commercial software, like Siemens
NX, that are specifically designed for hybrid cycles involving
additive and subtractive manufacturing, but they mainly
address laser beam additive technologies, with limited
flexibility to address feedstock extrusion processes. On the
other side, when dealing with FDM slicers as the tested ones,
typically adopted with polymers deposition, the needs and
constraints of a hybrid implementation involving milling are
7
flaking
flaking
surface damage
Figure 10: Shell/perimeter milling (a), Infill milling (b)
not taken into consideration. For this reason, specific
adjustments were required and were developed in this work.
All the dog-bone specimens deposited with the three
different software, discussed in paragraph 4.1, were milled in
green-state on their external surfaces, in order to understand
which printing solution could better support the parts
machinability.
A second geometry was studied during the experimental
printing campaign consisting in simple cubic samples with the
main purpose to study the layer integrity before and after
milling and to test the cutting of micro slotting on the sample
top surface (Fig. 10). The slots geometry was selected also for
analyzing the cutting forces and the achievable roughness on
the milled components.
It was found that milling tool and the induced cutting forces
tended to damage the parts and the deposited green-part
strands. Two main situations occurred. The first consists in the
damages of the upper part surface during flattening (Fig. 11 (f))
operation. In this case, a single layer detachment was usually
observed, mainly concentrated at the part outer borders, leading
to localized, but shallow, defects typically bigger than the
adopted milling tool diameter.
The other case is represented by the damages happening
when contouring the part. In this case, cracking formation and
shell detachment were systematically observed when the
shell/perimeter deposition strategy was adopted. Large
extension of the defects typically happened thus limiting the
capacity to obtain good parts. The reason could be linked to
localized lack of adhesion between the outer shells with the
inner one that, under cutting forces, produced a complete
fracture of the shell. This phenomenon was exacerbated by the
adoption of large radial amount of depth of cuts (ae in Fig.10
(a)). To avoid this defect, a deposition strategy without
shell/perimeters was selected. Infill was deposited with an
orientation of 45° and phase-shifted by 90° between each layer,
Fig.10 (b).
 Paolo Parenti et al. / Procedia Manufacturing 34 (2019) 738–746
8 Paolo Parenti / Procedia Manufacturing 00 (2019) 000–000
4.3. Green-part machinability
The feedstock material machinability depends upon many
factors. Multiple testing was executed on the produced
feedstock both in terms of milling and micromilling operations.
Tests of green parts executed with a sensorized machining
center confirm that milling forces keep low when machining
AISI316L green feedstock [17]. The cutting pressure resulted
in the order of 1/10 of the bulk material. Workpieces could then
sustain the forces and did not detach from the bed during the
cutting operations.
surface damages
Figure 11: Micromilled parts at green-state (a), (b), edge quality on green
part (c), air gaps on green part (d), milled slot on brown part (e), surface
defects in green-part (f)
Chip clogging and chip entrapment in the cutting area was
observed during cutting when cooling air was not provided. Air
cooling then resulted capable of refrigerating and cleaning the
contact area improving the machining results. Despite the use
of cooling air, workpiece bulk temperature seemed to play an
effect on the achievable surface quality. This is an important
aspect for the process planning since after deposition, the
cooling rate of the samples is quite slow, as can be observed in
Fig. 9. Since hot milling could be prescribed to reduce the
overall cycle time, feedstock must possess high machinability
also in hot-state.
Surface appearance of the green-state milled samples was
good and homogeneous without any apparent defects nor
relevant milling marks.
Milling operations were able to remove all the surface
irregularities. The overall surface roughness of the deposited
workpiece, originally around Sa ~ 70-120 μm, was reduced to
Sa = 1.4-2.8 μm in the top and lateral green part surfaces.
Some upper border damages appeared in the green part
because of air-gap formations (Fig. 11 (d)). Without taking
these local defects into consideration, an average Sa of 2.5 μm
was achieved on the sintered workpiece.
Good sharp edges were obtained with a radius lower than
100 μm, Fig. 11 (c). The Scanning Electron Microscopy (SEM)
conducted on milled feedstock revealed the achievement of no
745
surface voids with extremely sharp corners (Fig. 11 (b) and (e)).
Little binder segregation was observed in some cases, Fig. 12
(a), often aligned with the deposited strands direction.
However, this did not generate noticeable problems in the
sintered workpieces.
4.4. Debinding and Sintering
The type of debinding action for removing the binder from
the green part strictly depends upon the type and quantity of
binder adopted. In the tested case, a water debinding followed
by thermal debinding were adopted for all the samples.
Figure 12: SEM analysis of green milled parts (a), (b), and of
sintered parts (c), (d)
Water soluble binder was adopted and therefore a stirring
equipment with recirculating water at a temperature of 50 °C
was adopted for 10 hours. Samples were weighted showing
residual percentage of binder around 2.5-4% in weight, likely
related to the backbone binder content in the mix, removable
only by a thermal cycle.
Thermal debinding and pre-sintering phases were conducted
in hydrogen furnace at 680 °C for 10 hours. The brown and pre-
sintered components showed enough resistance and an overall
good integrity with no visible damages to features and surfaces,
Fig. 11 (e). No cracks were observed, however negligible
binder residues appeared in the SEM analysis of the upper
surface of the brown parts.
Then subsequent sintering was done in a 3% argon tube
furnace at a temperature of 1340 °C (1 hour), following the
prescription of the feedstock manufacturer.
A linear shrinkage of about 11.5 % occurred after sintering.
The components looked unaltered except for some small pores
due to deposition inaccuracies affecting some samples nearby
the upper corners and microcavities visible in the SEM analysis
Fig. 12 (d). Despite this fact, an overall density of 88-92% was
Figure 13: Some produced AISI316L parts after sintering
746 Paolo Parenti et al. / Procedia Manufacturing 34 (2019) 738–746
Paolo Parenti/ Procedia Manufacturing 00 (2019) 000–000
achieved on those sample without any apparent internal
delamination or cracking, as shown in Fig.13.
The produced samples are now undergoing mechanical
characterization to assess the material functional performances.
5. Conclusion
Among the several influencing facotrs that affect the tested
AISI316L feedstock extrusion deposition process, the most
important aspects resulted, above all, the extrusion temperature
and the deposition strategy. Interlayer adhesion and perimeter
generation played a key role for the generation of air gaps free
samples.
Milling of green-state feedstock resulted a viable way to
improved surface finish and obtain fine features with accurate
dimension on the green parts, that could resist to debinding and
sintering stages. Deposition strategies were designed to support
the machinability by avoiding layer detachment due to cutting
forces.
Machinability of the soft AISI 316L resulted good,
comparable with hot pressed material, with low achieved forces
that vary non-linearly with feed rate and show only slight
changes by varying the workpiece base temperature.
The given examples promote this novel hybrid
manufacturing approach, based on additive extrusion and
machining of feedstock, as a future tangible solution for the
industrial production of metallic and ceramic artifacts.
Future attention will be given to the mechanical
characterization of the produced components, to the design of
a novel machine architecture and to the testing of innovative
materials for the AM field [18].
Acknowledgements
The authors are grateful to V. Mussi (Musp) and G. De
Gaudenzi (Films S.p.A.) for their support.
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