HY5CAM

Keeping an overview with HY5CAM

Despite the increasing market penetration of additive manufacturing systems, parts are often only generated in three axes even though the available system equipment, such as robots, linear or parallel kinematics, allow for complex movements. These are often also hybrid-usable through automatic tool changes between DED as well as pellet FDM and mechanical processing. Equipment manufacturers and system integrators invest a lot of time in providing sophisticated hardware solutions and refining the equipment and technology modules contained within them over the years. However, after handover to the user, the problem often arises that the variety of options requires a learning curve and the equipment does not immediately produce the long-awaited 3D printed parts at the push of a button. 1A Technologies provides this button press based on a close cooperation with moduleworks GmbH and enables the production and repair of parts in full, regardless of the kinematics and technology used, both additively and subtractively, in the HY5CAM software. The collaboration started on the basis of a customer project with Bionic Production GmbH, which makes the „Mobile Smart Factory“ available as a production environment in a container on site. The container solution makes it possible to generate parts at the customer’s site or on the way there (by ship or railway) independently of the external conditions, with only an external power connection of 63 amperes. The so-called WAAM process or wire DED is used here, as well as the automatic tool change to measuring probes or milling tools for intermediate and final processing of the parts. One main application of the Mobile Smart Factory is the fast delivery of parts on demand in small quantities. An example is the casing of a windshield wiper motor of a seagoing vessel, which must be replaced due to corrosion affecting the function of the windshield wiper, in order to guarantee safe further travel.

Scan

In the field of spare parts manufacturing, the complete CAD data is often not available and stored in the form of drawings. In order to make manufacturing time and data preparation more effective, a CAD model of the part is created using the digitization tool contained in the container and, if necessary, post-processed at the defective areas and functional locations.

Interface

Subsequently, the digitized component is programmed using HY5CAM for both additive and subtractive manufacturing. With an enormous range of automated processes suitable for beginners, as well as complex algorithms adapted to the respective component, the generation of path planning is fast and intuitive.

Visualization

Afterwards, the tool paths for the respective kinematics used are transformed. A comprehensive collision consideration is possible from the machine, tool and workpiece to the clamping device, ensuring the optimal accessibility of all machining positions. In this case, the output was made for a hybrid parallel kinematic 6-axis machine type P700 from METROM Mechatronische Machinen GmbH, which forms the core of the mobile smart factory.

Manufacturing

The component is carried out inside the sea container first using the WAAM process, applying an automatic interlayer temperature control. This is selectable in the post-processor and implemented through the control functions of the machine.

The result is a component that is completed to the full satisfaction of the customer in a very short time, thanks to the collaboration of all partners involved.