Proceedings of the XMO Industrial Seminar 2026: Excellence in Manufacturing and Operations
Keywords
Hybrid deformation aided deposition process; Non-planar deposition; Reconfigurable tooling; Resource efficiency
Tracks
CONVERGENT MANUFACTURING
DOI
10.5703/1288284318676
Abstract
Flexible and hybrid processes play an important role in smart manufacturing by enabling adaptable, resource-efficient and eco-friendly fabrication strategies. In this work a hybrid combination of Double Sided Incremental Forming (DSIF), Reconfigurable Tooling (RT) and Wire-based Directed Energy Deposition (WDED) is proposed to utilize non-planar sheet metal substrates during metal additive manufacturing. The approach aimed to explore the geometrical freedom offered by DSIF and tailored thermal and mechanical support provided by RT to reduce support structure requirements, substrate deformation and component distortion. Experimental studies demonstrate successful fabrication of complex geometries, improved dimensional accuracy and enhanced surface quality through suitable process parameters.
Resource Efficient Hybrid Manufacturing: Integration of Reconfigurable Tooling, Flexible Deformation and Non-Planar Deposition
Flexible and hybrid processes play an important role in smart manufacturing by enabling adaptable, resource-efficient and eco-friendly fabrication strategies. In this work a hybrid combination of Double Sided Incremental Forming (DSIF), Reconfigurable Tooling (RT) and Wire-based Directed Energy Deposition (WDED) is proposed to utilize non-planar sheet metal substrates during metal additive manufacturing. The approach aimed to explore the geometrical freedom offered by DSIF and tailored thermal and mechanical support provided by RT to reduce support structure requirements, substrate deformation and component distortion. Experimental studies demonstrate successful fabrication of complex geometries, improved dimensional accuracy and enhanced surface quality through suitable process parameters.