Design and validation of a sheet metal clamping system for additive manufacturing and post-processing

Automated clamping for post-processing of mass-customized parts is a challenging step in the laser powder bed fusion (LPBF) process chain. In this study, a novel modular sheet metal clamping system was developed that uses disposable sheet metal profiles as a universal interface for the LPBF, robotic handling, and milling processes. Based on a fundamental investigation of hybrid additive manufacturing, the sheet metal clamping system was designed to use the same interface for the LPBF and milling processes. Subsequent an end-to-end validation was performed for the entire process chain. The concept of the sheet metal clamping system gives milling tools access to a part on five to six sides. Further, the part can be accessed from the top and bottom sides, and simplifying the removal of LPBF supports. No clamping forces are induced in the LPBF part, which is especially important for filigree structures. The sheet metal clamping system’s underlying concept could be adapted to automating the LPBF process chain for applications such as prosthetic dentistry.