Enabling automated post-processing for Additive Manufacturing using integrated bolts for clamping and handling

Abstract

Additive Manufacturing (AM), especially Selective Laser Melting (SLM) enables the fabrication of complex and customized metal parts. However, 35 - 40 % of the manufacturing costs are required for manual post-processing steps. In order to reduce the cost of extensive post-processing, the process chain for AM parts must to be automated. In this respect, the robotic gripping and handling for the efficient clamping and machining is regarded as a key challenge. This work introduces bolts as a new universal interface for handling and clamping for the mass customization of AM parts. The SLM manufactured bolts are integrated in the part design and manufactured in the same AM process. The bolts can be easily removed after the machining process using a wrench. The application of the bolts is highlighted in two case studies. In this regard, the major contribution of this paper is the generated increased AM design freedom by adding universal clamping interfaces. The five side tool accessibility reduces the number of re-clamping. Finally no internal stress in the SLM part is induced by the clamping. This contributions further enable minimum lead time and mass customization for automated industrial series production