This book focuses on the emerging additive manufacturing technology and its applications beyond state-of-the-art, fibre-reinforced thermoplastics. It also discusses the development of a hybrid, integrated process that combines additive and subtractive operations in a single-step platform, allowing CAD-to-Part production with freeform shapes using long or continuous fibre-reinforced thermoplastics. The book covers the entire value chain of this next-generation technology, from part design and materials composition to transformation stages, product evaluation, and end-of-life studies. Moreover, it addresses the following engineering issues: • Design rules for hybrid additive manufacturing; • Thermoplastic compounds for high-temperature and -strength applications; • Advanced extrusion heads and process concepts; • Hybridisation strategies; • Software ecosystems for hAM design, pre-processing, process planning, emulating and multi-axis processing; • 3D path generators for hAM based on a multi-objective optimisation algorithm that matches the recent curved adaptive slicing method with a new transversal scheme; • hAM parameters, real-time monitoring and closed-loop control; • Multiparametric nondestructive testing (NDT) tools customised for FRTP AM parts; • Sustainable manufacturing processes validated by advanced LCA/LCC models.

The text presents the latest research and development, technical challenges, and future directions in the field of hybrid metal additive manufacturing. It further discusses the modeling of hybrid additive manufacturing processes for metals, hybrid additive manufacturing of composite materials, and low-carbon hybrid additive manufacturing processes. THIS BOOK •Presents cutting-edge advancements and limitations in hybrid additive manufacturing technologies. • Discusses fabrication methods and rapid tooling techniques focusing on metals, composites, and alloys. •Highlights the importance of low-carbon additive manufacturing technologies toward achieving sustainability. •Emphasizes the challenges and solutions for integrating additive manufacturing and Industry 4.0 to enable rapid manufacturing of customized and tailored products. • Covers hybrid additive manufacturing of composite materials and additive manufacturing for fabricating high-hardness components. The text discusses the recent advancements in additive manufacturing of high-hardness components and covers important engineering materials such as metals, alloys, and composites. It further highlights defects and post-processing of hybrid additive manufacturing components, sustainability solutions for hybrid additive manufacturing processes, and recycling of machining waste into metal powder feedstock. It will serve as an ideal reference text for senior undergraduate and graduate students, and researchers in fields including mechanical engineering, aerospace engineering, manufacturing engineering, and production engineering.

Hybrid Additive Manufacturing: Techniques, Applications and Benefits explains the fundamentals of hybrid AM, definitions, classifications, and principles, as well as key techniques of hybrid AM, its applications, design guidelines, and benefits, with emphasis on key aspects of the system integration process. The core of this subject is in describing how to overcome inherent processing limitations of layer-by-layer AM through the integration of secondary post-processing such as machining or heat treatment. As a result hybrid AM plays a critical role in accelerating the adoption of AM in established design and manufacturing activities. The applications of hybrid AM in both metals and polymers are discussed in this book, as are geometrical dimensioning and tolerancing, material property enhancement, non-traditional surface finishing, in-situ sequential hybrid processing, and integrated process planning. This book will serve not only as an introduction to hybrid AM but also as a handbook for researchers and engineers in mechanical, manufacturing, industrial, electronics, and materials science, thanks to its interdisciplinary approach and detailed case studies. Explains how hybrid manufacturing processes can be used to achieve enhanced material properties and functionality Describes the significance of hybrid additive manufacturing to different parts of the process chain Uses case studies to show how innovative companies are using this technology, how they have overcome challenges they encountered, and the benefits they have experienced

This textbook covers in detail digitally-driven methods for adding materials together to form parts. A conceptual overview of additive manufacturing is given, beginning with the fundamentals so that readers can get up to speed quickly. Well-established and emerging applications such as rapid prototyping, micro-scale manufacturing, medical applications, aerospace manufacturing, rapid tooling and direct digital manufacturing are also discussed. This book provides a comprehensive overview of additive manufacturing technologies as well as relevant supporting technologies such as software systems, vacuum casting, investment casting, plating, infiltration and other systems. Reflects recent developments and trends and adheres to the ASTM, SI and other standards; Includes chapters on topics that span the entire AM value chain, including process selection, software, post-processing, industrial drivers for AM, and more; Provides a broad range of technical questions to ensure comprehensive understanding of the concepts covered.

This book explores, in a systematic way, both conventional and unconventional material shaping processes with various modes of hybridization in relation to theory, modelling and industrial potential. The demand for high productivity and high accuracy in manufacturing is continuously increasing, based on improvement and optimization strategies. Hybridization of manufacturing processes will play a crucial role and will be of a key importance in achieving environmental and economical sustainability. Structured in three parts, Hybrid Manufacturing Processes summarizes the state-of-the art hybrid manufacturing processes based on available literature sources and production reports. The book begins by providing information on the physical fundamentals of the removal and non-removal processes in macro-, micro and nanoscales. It then follows with an overview of the possible ways of hybridization and the effects on the enhancement of process performance, before concluding with a summary of production outputs related to surface integrity, specifically with respect to difficult-to-machine materials. Considering the applications of different sources of hybridization including mechanical, thermal and chemical interactions or their combinations, this book will be of interest to a range of researchers and practicing engineers within the field of manufacturing.

Additive Manufacturing of Titanium Alloys: State of the Art, Challenges and Opportunities provides alternative methods to the conventional approach for the fabrication of the majority of titanium components produced via the cast and wrought technique, a process which involves a considerable amount of expensive machining. In contrast, the Additive Manufacturing (AM) approach allows very close to final part configuration to be directly fabricated minimizing machining cost, while achieving mechanical properties at least at cast and wrought levels. In addition, the book offers the benefit of significant savings through better material utilization for parts with high buy-to-fly ratios (ratio of initial stock mass to final part mass before and after manufacturing). As titanium additive manufacturing has attracted considerable attention from both academicians and technologists, and has already led to many applications in aerospace and terrestrial systems, as well as in the medical industry, this book explores the unique shape making capabilities and attractive mechanical properties which make titanium an ideal material for the additive manufacturing industry. Includes coverage of the fundamentals of microstructural evolution in titanium alloys Introduces readers to the various Additive Manufacturing Technologies, such as Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) Looks at the future of Titanium Additive Manufacturing Provides a complete review of the science, technology, and applications of Titanium Additive Manufacturing (AM)

Get Ready for the Future of Additive ManufacturingAdditive Manufacturing: Innovations, Advances, and Applications explores the emerging field of additive manufacturing (AM)-the use of 3D printing to make prototype parts on demand. Often referred to as the third industrial revolution, AM offers many advantages over traditional manufacturing. This pr