Hybrid Manufacturing Takes Polymer Part Production to the Next Level

When one talks about hybrid manufacturing, they are typically referring to a production approach that combines subtractive manufacturing processes—like CNC machining—and additive manufacturing technologies—such as extrusion 3D printing. With contrasting strengths and weaknesses, these two processes complement each other and integrating them in a hybrid solution can enable manufacturers to exploit the benefits of each production approach while minimizing their limitations.

SmartZavod, a German-Ukrainian startup specializing in industrial production, is bringing to market an innovative hybrid manufacturing solution for polymer materials. While some hybrid approaches rely on two separate systems to execute the additive and subtractive processes, SmartZavod has integrated the two into a single, highly automated system called the SmartZavod GENx. As we’ll see in more depth, this integrated technology enables users to manufacture high-precision parts from a range of polymer materials.

Why Hybrid is Superior

Hybrid manufacturing is an increasingly popular production approach because it combines the strengths of 3D printing and CNC machining. In terms of 3D printing, the technology has a number of benefits, including agile production, minimal material waste, the ability to produce customized products, and perhaps above all, design freedom. But it is also limited when it comes to producing parts with exact tolerances and ultra-smooth surface finishes. CNC machining, for its part, is capable of achieving the tightest production tolerances but is associated with significant material wastage and design limitations. Used together, manufacturers can avoid the pitfalls of each technology while benefiting from their capabilities. 

The SmartZavod team, which has to date raised €300k in funding, was quick to see the potential of hybrid manufacturing for polymer part production. With support from academic institutions and industrial partners, the team has worked for the past three years to develop its hybrid manufacturing hardware solution. This highly automated and modular system, which consists of a patented mechatronic platform, was engineered to meet the sustainability goals of Industry 5.0 and is capable of producing complex geometries and multi-material components without generating material waste and minimizing energy usage through its lightweight architecture.

Like other additive manufacturing solutions, the hybrid system is also well positioned to meet the growing demand for personalized products and even mass customization. Additive manufacturing is a key enabler of scalable customization, as the design of a product does not influence the cost of manufacturing it, as is the case with more conventional production methods, such as injection molding. In other words, the ability to easily adjust 3D designs and print on demand makes personalization possible and efficient. 

How the GENx System Works

SmartZavod’s GENx system is a unique approach to hybrid manufacturing. While some existing systems use a robotic arm to control the additive and subtractive functions, SmartZavod has pioneered a delta setup that is capable of both multi-material polymer 3D printing and high-tolerance CNC machining thanks to a patented tool change system.

In short, the hybrid system works by first depositing layers of material using a extrusion tool onto the build surface to create a near net shape. From there, the system automatically changes tools, exchanging the print head for a CNC machining tool that precisely trims the edges of the printed layers to meet the correct tolerances of the original CAD design. Both the printhead and machining tool are controlled by a proprietary kinematic moving system, which ensures precise and fast motion and can make the most out of the machine’s available working area (up to 600 x 800 mm).

Notably, the tool change system that enables the hybrid functionality of the GENx system also enables users to print using multiple materials. According to SmartZavod, the whole system is modular and can be fitted with customized tool sets based on end user needs. The company’s first system, the GEN1, can be fitted with three tools (i.e. the Dyze Design Pro, Dyze Design Typhoon, and Mechatron High Speed Spindle) and three axes, however a customized system can have up to six tool positions and six working axes. Tools can include the aforementioned extruders and spindle as well as dosing and mixing tools for printing compounds, spraying tools for applying coatings, and measuring touch sensors for further automating quality control assessments.

When the 3D print is completed and the required tolerances and features have been achieved thanks to the subtractive machining process, the GENx system is equipped with an automated part removal system. This feature uses a carbon-based printing surface and segmented heating zones so that parts detach automatically without the need for any prying or cutting off the build plate. As any maker or 3D printer user will know, this small automation can save a ton of time and energy. 

Built for industrial applications, SmartZavod’s hybrid solution is compatible with a wide range of materials, including engineering-grade polymers, composites, silicones, and ceramics. This wide material variety is possible thanks to the printhead’s ability to reach extrusion temperatures of up to 500 °C. As mentioned, these materials can be combined in a single print for a wider array of part functionalities.

Hybrid Manufacturing in Action

SmartZavod’s hybrid manufacturing solution has a wide range of potential applications that can transform how products are made. At present, the company is in the final stages of system development (according to the Technology Readiness Levels system, the company is at least at stage seven out of nine) and is seeking more use case partners for its platform. In parallel, the company is also raising €1.5 million to further advance and commercialize its solution.

For now and the foreseeable future, SmartZavod is aiming to make its technology more accessible to customers through a service business model. For example, the hybrid 3D printer could be installed in university labs or innovation hubs, where startups and small-to-medium-sized businesses could order parts via a web platform. “This way, businesses can get access to advanced technology without the need to invest in equipment,” said Oleksii Solntsev, SmartZavod CEO.

The innovative startup and its technology have already participated in three pilot projects in partnership with OSV LLC Poland, the Manufacturing Innovation Valley in Lithuania, and the children’s clinic Kyiv. The pilot project with OSV LLCOSV LLC, a small-series manufacturer from Poland specialized in manufacturing mixing and dosing equipment for polyurethanes and silicones, consisted of producing a two-part component for a dosing-mixing system. The main component, traditionally made from aluminum, was printed from PA 6 and post-processed on the spot using SmartZavod’s integrated hybrid solution. From there, a third tool was used to print a silicone seal on top of the PA 6 print, and the finished part was removed automatically from the build surface. 

In the end, SmartZavod’s technology offered OSV several benefits, including 50% reduction in cost per part, 70% less labor time, 30% lower labor costs, as well as minimized energy consumption and material waste, all while meeting the specifications of the original part. This partnership was organized through the Horizon 2020 funding program.

Collaboration Opportunities

In addition to startups and small manufacturing businesses, SmartZavod is also interested in targeting larger manufacturing enterprises as clients, as they could benefit from its flexible and highly automated hybrid production. For instance, the company is currently working on use cases with two major manufacturers.

“We communicate with potential customers, study their requests, create the necessary products in-house, send them for testing, receive feedback, and improve the model,” Oleksii explained in a recent interview. “Our potential customers currently include two large manufacturing companies, ten medium-sized ones, and five small ones. In the near future, we aim to engage in five solid use cases, which we anticipate will enable our transition to TRL 8 and facilitate our first sales, especially through agreements with customers already participating in pilot programs with SmartZavod.”

In sum, SmartZavod is continually improving its hardware solution based on user feedback to enhance the system process and performance. As the young company advances towards the full maturation of its solution, it aims to be a key player in the ushering in of Industry 5.0, which places an increasingly important focus on sustainability and societal value. 

Get in touch with them via their website here.