This thesis details the creation and application of a generalized process plan for the hybrid manufacturing of AISI 316L stainless steel, using direct energy deposition (DED) and ball-nose end-mill machining, that includes the inspection and measurement of objects created by that hybrid manufacturing process plan. The proposed process plan progresses through the selection of substrate thickness, single-track, multi-track, and multi-layer depositions, then on to machining processing. A manufacturers' recommended set and range of DED parameters were used to create a designed experiment that aided in the analysis of objects created in each of the DED process planning steps; those objects were then machined in the same enclosure using a set of machining parameters screened from industry recommendations for ball-nose milling of stainless steel, after which measurements were taken for surface roughness, some material characteristics, and for tool deterioration. The results, analyses, and discussions collected herein show that the proposed process plan can provide models for geometrical outputs for each step in the plan, some improvements in substrate stability, surface roughness, tool deterioration, and material porosity due to voids. Current research in hybrid manufacturing does not show generalized process planning influences. The process plan as demonstrated by the work in this thesis will help operators, designers, and researchers in the future by defining a generalized workflow that can be applied to other materials used in hybrid manufacturing.

The work is focused on introduction and brief description of CAM software PowerMill 2020 from a company named Autodesk. Furthermore, this thesis discusses the issue of CAD/CAM systems, especially additive manufacturing. Description, division, technology, materials and area of application of additive manufacturing including advantages and disadvantages are discussed. The work also includes the issue of hybrid manufacturing and introduces the most important companies operating in this area of production. The practical part of the thesis is mainly focused on outlining the machining process of own designed part in the PowerMILL2020.

<p dir="ltr">In pursuit of enhanced fuel economy, the automotive industry is exploring the substitution of metal components with lightweight polymer composites. These components must withstand elevated static loading and crash performance, while ideally offering added functionalities and reduced weight. To tackle these challenges, this research presents an innovative manufacturing method aimed at reducing costs and cycle times associated with continuous fiber polymer composites. This method involves producing a linear thermoplastic composite rod known as M-TOW (Multi-tow), which can be molded into intricate shapes to serve as tailored structural reinforcement in hybrid-molded parts. The research encompasses the processing of M-TOW, with a focus on predicting consolidation using Darcy’s law, integrating functional components for thermal and electrical conductivity using overbraided metallic wire or sensing using optical fibers, and its application in real-world scenarios. These advancements showcase the versatility and potential of M-TOW in high-rate continuous fiber manufacturing, paving the way for multifunctional hybrid molded structures.<br><br></p>