Design of a high precision hybrid AM machine

Thesis Type: Postgraduate

Institution Of The Thesis: Middle East Technical University, Faculty of Engineering, Department of Mechanical Engineering, Turkey

Approval Date: 2019

Thesis Language: English

Student: Yunus Emre Yılmaz

Principal Consultant (For Co-Consultant Theses): Melik Dölen

Co-Consultant: Ulaş Yaman


Precision requirements in fused deposition modelling (FDM) processes have been increasing in recent years, especially after recognizing the potential of FDM process to produce complex and functional components. In order to increase precision of FDM process, 6-axis hybrid manufacturing system, which can carry out additive- and subtractive manufacturing processes in one manufacturing system platform, is designed. During design, kinematic analysis of the machine is done, axial- and angular errors are estimated by Monte Carlo simulation and components of linear- and rotary bearings are selected based on the model constructed to identify the axial and radial errors of the linear- and rotary axis. Furthermore, other machine components such as structures and transmission and actuation as well as sensor selection processes are explained. The components of the structure, four linear axes and the rotary stage components are manufactured and assembled, while spindle and extruder head planned to be manufactured in near future.