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Hybrid Additive Manufacturing

Hybrid Additive Manufacturing
Techniques, Applications and Benefits

by Guha Manogharan

  • Publisher : Academic Press
  • Release : 2020-07
  • Pages : 350
  • ISBN : 9780128181706
  • Language : En, Es, Fr & De
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Hybrid Additive Manufacturing: Techniques, Applications and Benefits explains the fundamentals of hybrid AM, definitions, classifications, and principles, as well as key techniques of hybrid AM, its applications, design guidelines, and benefits, with emphasis on key aspects of the system integration process. The core of this subject is in describing how to overcome inherent processing limitations of layer-by-layer AM through the integration of secondary post-processing such as machining or heat treatment. As a result hybrid AM plays a critical role in accelerating the adoption of AM in established design and manufacturing activities. The applications of hybrid AM in both metals and polymers are discussed in this book, as are geometrical dimensioning and tolerancing, material property enhancement, non-traditional surface finishing, in-situ sequential hybrid processing, and integrated process planning. This book will serve not only as an introduction to hybrid AM but also as a handbook for researchers and engineers in mechanical, manufacturing, industrial, electronics, and materials science, thanks to its interdisciplinary approach and detailed case studies. Explains how hybrid manufacturing processes can be used to achieve enhanced material properties and functionality Describes the significance of hybrid additive manufacturing to different parts of the process chain Uses case studies to show how innovative companies are using this technology, how they have overcome challenges they encountered, and the benefits they have experienced

Additive Manufacturing Hybrid Processes for Composites Systems

Additive Manufacturing Hybrid Processes for Composites Systems
A Book

by António Torres Marques,Sílvia Esteves,João P. T. Pereira,Luis Miguel Oliveira

  • Publisher : Springer Nature
  • Release : 2020-04-27
  • Pages : 329
  • ISBN : 3030445224
  • Language : En, Es, Fr & De
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This book focuses on the emerging additive manufacturing technology and its applications beyond state-of-the-art, fibre-reinforced thermoplastics. It also discusses the development of a hybrid, integrated process that combines additive and subtractive operations in a single-step platform, allowing CAD-to-Part production with freeform shapes using long or continuous fibre-reinforced thermoplastics. The book covers the entire value chain of this next-generation technology, from part design and materials composition to transformation stages, product evaluation, and end-of-life studies. Moreover, it addresses the following engineering issues: • Design rules for hybrid additive manufacturing; • Thermoplastic compounds for high-temperature and -strength applications; • Advanced extrusion heads and process concepts; • Hybridisation strategies; • Software ecosystems for hAM design, pre-processing, process planning, emulating and multi-axis processing; • 3D path generators for hAM based on a multi-objective optimisation algorithm that matches the recent curved adaptive slicing method with a new transversal scheme; • hAM parameters, real-time monitoring and closed-loop control; • Multiparametric nondestructive testing (NDT) tools customised for FRTP AM parts; • Sustainable manufacturing processes validated by advanced LCA/LCC models.

A Hybrid Additive Manufacturing Framework for the Multi-phase Fabrication and In-line Characterization of Functional Devices

A Hybrid Additive Manufacturing Framework for the Multi-phase Fabrication and In-line Characterization of Functional Devices
A Book

by Lukas Fieber

  • Publisher : Unknown Publisher
  • Release : 2020
  • Pages : 329
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Design and Analysis of a Hybrid Subtractive and Additive Manufacturing Unit

Design and Analysis of a Hybrid Subtractive and Additive Manufacturing Unit
A Book

by Farhad Ghadamli

  • Publisher : Unknown Publisher
  • Release : 2017
  • Pages : 329
  • ISBN : 9780355763201
  • Language : En, Es, Fr & De
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Automation in production of 3D printed parts, hybrid additive and subtractive machines, and post-processing of 3D printed parts are rapidly growing fields. Given the numerous advancements in the 3D printing industry as reported in this thesis, the lack of availability of a Do It Yourself (DIY) and low-cost hybrid additive and subtractive unit is identified and tackled. This thesis covers the mechanical design of a low-cost DIY, hybrid additive and subtractive unit using a robot arm to remove the 3D printing support structures. Since the removal of printed support structures has not been investigated in the scientific literature, in a first step, different cutting tools and speeds were analyzed with a hand-held Dremel 4000 power tool with regard to cut quality and cutting forces. An off-the-shelf tool bit, a High-Speed steel cutter, at 15000 rpm yielded the best results. Furthermore, a hybrid machine was conceptualized, consisting of additive and subtractive subsystems. The constraints are a working volume of 6 cubic inches and costs below $5000. The additive system is based on following components: X, Y and Z Motor Holders, Filament Holder, and 3D Printing Arm, which can be printed by the DIY user, and off-the-shelf hardware like NEMA 17 stepper motors. The subtractive system is based on the following components: Motor Holder, Linkbot Mounting Interface, and Connector Arm, which are also designed to be 3D printed by the DIY users. For both subsystems, the off-the-shelf parts are specified, and technical drawings for 3D printing and assembly are provided. The critical 3D printed parts are analyzed with regard to their maximum distortion and strength during operation.

A New Hybrid Additive Manufacturing Process Combining Selective Laser Melting and Laser Shock Peening

A New Hybrid Additive Manufacturing Process Combining Selective Laser Melting and Laser Shock Peening
A Book

by Nikola Kalentics

  • Publisher : Unknown Publisher
  • Release : 2018
  • Pages : 161
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Mots-clés de l'auteur: Selective Laser Melting ; Laser Shock Peening ; 3D LSP ; residual stresses ; microstructure ; recrystallization ; microhardness ; distortion ; fatigue life ; crack density.

Additive Manufacturing

Additive Manufacturing
Science and Technology

by Emrah Celik

  • Publisher : Walter de Gruyter GmbH & Co KG
  • Release : 2020-07-06
  • Pages : 151
  • ISBN : 150151878X
  • Language : En, Es, Fr & De
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This book covers additive manufacturing of polymers, metals, ceramics, fiber reinforced polymer composites, energy harvesting materials, and biomaterials. Hybrid manufacturing is discussed. Topology optimization methodology is described and finite element software examples are provided. The book is ideal for graduate students and career starters in the industry.

Systems, Materials, and Methodologies for Multi-material Hybrid Additive Manufacturing Functionally Graded Structures

Systems, Materials, and Methodologies for Multi-material Hybrid Additive Manufacturing Functionally Graded Structures
A Book

by Esmat Sheydaeian

  • Publisher : Unknown Publisher
  • Release : 2017
  • Pages : 121
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Modeling Residual Stress Development in Hybrid Processing by Additive Manufacturing and Laser Shock Peening

Modeling Residual Stress Development in Hybrid Processing by Additive Manufacturing and Laser Shock Peening
A Book

by Guru Charan Reddy Madireddy

  • Publisher : Unknown Publisher
  • Release : 2018
  • Pages : 127
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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The term “hybrid” has been widely applied to many areas of manufacturing. Naturally, that term has found a home in additive manufacturing as well. Hybrid additive manufacturing or hybrid-AM has been used to describe multi-material printing, combined machines (e.g., deposition printing and milling machine center), and combined processes (e.g., printing and interlayer laser re-melting). The capabilities afforded by hybrid-AM are rewriting the design rules for materials and adding a new dimension in the design for additive manufacturing paradigm. This work focuses on hybrid-AM processes, which are defined as the use of additive manufacturing (AM) with one or more secondary processes or energy sources that are fully coupled and synergistically affect part quality, functionality, and/or process performance. Secondary processes and energy sources include subtractive and transformative manufacturing technologies, such as machining, re-melting, peening, rolling, and friction stir processing. Of particular interest to this research is combining additive manufacturing with laser shock peening (LSP) in a cyclic process chain to print 3D mechanical properties. Additive manufacturing of metals often results in parts with unfavorable mechanical properties. Laser shock peening is a high strain rate mechanical surface treatment that hammers a work piece and induces favorable mechanical properties. Peening strain hardens a surface and imparts compressive residual stresses improving the mechanical properties of the material. The overarching objective of this work is to investigate the role LSP has on layer-by-layer processing of 3D printed metals. As a first study in this field, this thesis primarily focuses on the following: (1) defining hybrid-AM in relation to hybrid manufacturing and classifying hybrid-AM processes and (2) modeling hybrid-AM by LSP to understand the role of hybrid process parameters on temporal and spatial residual stress development. A finite element model was developed to help understand thermal and mechanical cancellation of residual stress when cyclically coupling printing and peening. Results indicate layer peening frequency is a critical process parameter and highly interdependent on the heat generated by the printing laser source. Optimum hybrid process conditions were found to exists that favorably enhance mechanical properties. With this demonstration, hybrid-AM has ushered in the next evolutionary step in additive manufacturing and has the potential to profoundly change the way high value metal goods are manufactured.

A New Additive Manufacturing Technique for Layered Metal-composite Hybrid Structures

A New Additive Manufacturing Technique for Layered Metal-composite Hybrid Structures
A Book

by Rielson Falck

  • Publisher : Unknown Publisher
  • Release : 2020
  • Pages : 329
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Additive Manufacturing Technologies

Additive Manufacturing Technologies
A Book

by Ian Gibson,David Rosen,Brent Stucker,Mahyar Khorasani

  • Publisher : Springer Nature
  • Release : 2020-11-10
  • Pages : 675
  • ISBN : 3030561275
  • Language : En, Es, Fr & De
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This textbook covers in detail digitally-driven methods for adding materials together to form parts. A conceptual overview of additive manufacturing is given, beginning with the fundamentals so that readers can get up to speed quickly. Well-established and emerging applications such as rapid prototyping, micro-scale manufacturing, medical applications, aerospace manufacturing, rapid tooling and direct digital manufacturing are also discussed. This book provides a comprehensive overview of additive manufacturing technologies as well as relevant supporting technologies such as software systems, vacuum casting, investment casting, plating, infiltration and other systems. Reflects recent developments and trends and adheres to the ASTM, SI and other standards; Includes chapters on topics that span the entire AM value chain, including process selection, software, post-processing, industrial drivers for AM, and more; Provides a broad range of technical questions to ensure comprehensive understanding of the concepts covered.

Additive Manufacturing Volume 2

Additive Manufacturing Volume 2
Alloy Design and Process Innovations

by Prashanth Konda Gokuldoss,Zhi Wang

  • Publisher : MDPI
  • Release : 2020-04-15
  • Pages : 352
  • ISBN : 3039284142
  • Language : En, Es, Fr & De
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Additive manufacturing (AM) is one of the manufacturing processes that warrants the attention of industrialists, researchers and scientists, because of its ability to produce materials with a complex shape without theoretical restrictions and with added functionalities. There are several advantages to employing additive manufacturing as the primary additive manufacturing process. However, there exist several challenges that need to be addressed systematically. A couple such issues are alloy design and process development. Traditionally alloys designed for conventional cast/powder metallurgical processes were fabricated using advanced AM processes. This is the wrong approach considering that the alloys should be coined based on the process characteristics and meta-stable nature of the process. Hence, we must focus on alloy design and development for AM that suits the AM processes. The AM processes, however, improve almost every day, either in terms of processing capabilities or processing conditions. Hence, the processing part warrants a section that is devoted to these advancements and innovations. Accordingly, the present Special Issue (book) focuses on two aspects of alloy development and process innovations. Here, 45 articles are presented covering different AM processes including selective laser melting, electron beam melting, laser cladding, direct metal laser sintering, ultrasonic consolidation, wire arc additive manufacturing, and hybrid manufacturing. I believe that this Special Issue bears is vital to the field of AM and will be a valuable addition.

A Practical Guide to Design for Additive Manufacturing

A Practical Guide to Design for Additive Manufacturing
A Book

by Olaf Diegel,Axel Nordin,Damien Motte

  • Publisher : Springer
  • Release : 2019-05-21
  • Pages : 226
  • ISBN : 9811382816
  • Language : En, Es, Fr & De
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This book provides a wealth of practical guidance on how to design parts to gain the maximum benefit from what additive manufacturing (AM) can offer. It begins by describing the main AM technologies and their respective advantages and disadvantages. It then examines strategic considerations in the context of designing for additive manufacturing (DfAM), such as designing to avoid anisotropy, designing to minimize print time, and post-processing, before discussing the economics of AM. The following chapters dive deeper into computational tools for design analysis and the optimization of AM parts, part consolidation, and tooling applications. They are followed by an in-depth chapter on designing for polymer AM and applicable design guidelines, and a chapter on designing for metal AM and its corresponding design guidelines. These chapters also address health and safety, certification and quality aspects. A dedicated chapter covers the multiple post-processing methods for AM, offering the reader practical guidance on how to get their parts from the AM machine into a shape that is ready to use. The book’s final chapter outlines future applications of AM. The main benefit of the book is its highly practical approach: it provides directly applicable, “hands-on” information and insights to help readers adopt AM in their industry

Additive Manufacturing

Additive Manufacturing
Fundamentals and Advancements

by Manu Srivastava,Sandeep Rathee,Sachin Maheshwari,TK Kundra

  • Publisher : CRC Press
  • Release : 2019-09-17
  • Pages : 286
  • ISBN : 1351049372
  • Language : En, Es, Fr & De
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There is a growing need for manufacturing optimization all over the world. The immense market of Additive Manufacturing (AM) technologies dictates a need for a book that will provide knowledge of the various aspects of AM for anyone interested in learning about this fast-growing topic. This book disseminates knowledge of AM amongst scholars at graduate level, post graduate level, doctoral level, as well as industry personnel. The objective is to offer a state-of-the-art book which covers all aspects of AM and incorporates all information regarding trends, historical developments, classifications, materials, tooling, software issues, dynamic design, principles, limitations, and communication interfaces in a one-stop resource. Features: Breaks down systematic coverage of various aspects of AM within four distinct sections Contains details of various AM techniques based on ASTM guidelines Discusses many AM applications with suitable illustrations Includes recent trends in the field of AM Covers engineering materials utilized as raw materials in AM Compares AM techniques with different traditional manufacturing methods

Automatic Process Planning For a Five-Axis Additive Hybrid Manufacturing System

Automatic Process Planning For a Five-Axis Additive Hybrid Manufacturing System
A Book

by Xinyi Xiao

  • Publisher : Unknown Publisher
  • Release : 2020
  • Pages : 329
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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A multi-axis additive manufacturing (AM) system allows for reorienting of the geometry during a build to gain greater building flexibility over that of traditional planar layer by layer additive manufacturing processes. A hybrid manufacturing (HM) system integrates computer numerical control (CNC) machining with multi-axis AM into one process that can switch between each of these two processes, reaping the benefits of both. Currently, these two systems require significant manual work to transform the CAD design into a manufactured part. With the lack of automated process planning algorithms to avoid the significant amount manual work necessary, adoption of HM technology has been slow. Critical components of process planning in multi-axis AM and HM include: 3D model decomposition, sequencing of production of the decomposed volumes, and toolpath generation. Three process planning approaches are presented in this dissertation which seek to reduce the manual work required by automating each of the critical components. The first two approaches rely on the concept of generating decomposed volumes that are self-supported, and sequencing these volumes in a manner that avoids collisions between the build and the AM or HM system, then mapping tool path strategies to each of these volumes. The first approach treats the five-axis machine as a 3+2 axis machine, where the rotational axes are only used for positioning and the decomposed volumes only accommodate planar tool paths. The 2nd approach uses the full five-axis capability and 3D tool paths are used to decompose the part into self supported volumes that can be built without additional support structures. The 3rd approach, referred to as direct five-axis slicing, eliminates the volume decomposition and can directly generate the 3D slices, associating each slice with a tool path. All the approaches are focused on eliminating support structures and avoiding local collision between the tool and the part. Algorithms for decomposition are developed based on the process of identifying concave edges in a part's geometry and segmenting the part along these edges using the surfaces generated by the concave edges. For each decomposed volume, a build direction is identified along with the building sequence and toolpath strategy that can be used to generate the detailed toolpaths. Several case studies using the developed algorithms are presented, along with simulations and experimental results, to validate and showcase the capabilities of the three proposed process planning approaches. A comparison of the three approaches is also included to highlight the features and the limitations of each approach.

Advances in Manufacturing II

Advances in Manufacturing II
Volume 1 - Solutions for Industry 4.0

by Justyna Trojanowska,Olaf Ciszak,José Mendes Machado,Ivan Pavlenko

  • Publisher : Springer
  • Release : 2019-04-25
  • Pages : 458
  • ISBN : 3030187152
  • Language : En, Es, Fr & De
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This book covers a variety of topics related to the Industry 4.0 concept, with a special emphasis on the efficiency of production processes and innovative solutions for smart factories. It describes tools supporting this concept in both the mechanical engineering and biomedical engineering field. The content is based on papers presented at the 6th International Scientific-Technical Conference MANUFACTURING 2019, held on 19-22 May 2019, in Poznan, Poland. Virtual reality, simulation of manufacturing systems, additive manufacturing, big data analysis, automation and application of artificial intelligence, as well as economic and social issues related to the integration of those technologies are just some of the topics discussed here. All in all, the book offers a timely and practice-oriented reference guide for researchers and practitioners, and is expected to foster better communication and closer cooperation between universities and their business and industrial partners.

In and Ex-situ Process Development in Laser-based Additive Manufacturing

In and Ex-situ Process Development in Laser-based Additive Manufacturing
A Book

by Michael J. Juhasz

  • Publisher : Unknown Publisher
  • Release : 2020
  • Pages : 173
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Aircraft are currently flying much longer than their original design cycle with maintenance and logistics being paramount for keeping these aircraft flying. These aircraft require critical parts that may be out of production for a variety of reasons. This report is a subset of a larger project which looks to assess the role of additive manufacturing in assisting the aircraft supply chain with the production of spares and maintenance componentry. Addressed within the report is process development in both hybrid directed energy deposition additive manufacturing and laser powder bed fusion post-processing. Hybrid additive manufacturing combines additive manufacturing and traditional subtractive processing with synergistic layer-wise access. One benefit of an integrated, in-envelope suite of manufacturing processes is access to the structure at intermediate layers during fabrication. Implantation of sensors can inform the process of predictive maintenance and structural health management. These sensors can even support the qualification of the smart metal structures based on in-situ validation/qualification of the manufacturing process. Process development in this area will enable the next generation of aerospace components capable of providing sensing data from within the structure. This development resulted in the successful creation of proof-of-concept components which implemented both active and passive sensors. Laser powder bed fusion produced AlSi10Mg parts are being explored as a potential method for replacement of castings in aerospace applications. Maximizing the mechanical properties of this alloy is desirable to meet or exceed the performance of castings made of alloys such as A356. Like their traditionally produced counterparts, additively manufactured parts raise concerns about post-process induced distortion. Transverse isotropy and "as-produced" cellular microstructures also add to these concerns and are unique to LPBF parts. Here the results will be presented from a design of experiments examining the post processing conditions of hot isostatic pressing, quench rate, and the length and temperature of artificial aging against existing heat treatment schedules. For the first time, the post-processing heat treatment of AlSi10Mg to include hot isostatic pressing followed by precipitation hardening heat treatments has been significantly characterized with hot isostatic pressing being shown to accelerate artificial aging.

Hybrid Manufacturing

Hybrid Manufacturing
Analysis of Integrating Additive and Subtractive Methods

by Guhaprasanna Manogharan

  • Publisher : Unknown Publisher
  • Release : 2014
  • Pages : 187
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Advances in Additive Manufacturing, Modeling Systems and 3D Prototyping

Advances in Additive Manufacturing, Modeling Systems and 3D Prototyping
Proceedings of the AHFE 2019 International Conference on Additive Manufacturing, Modeling Systems and 3D Prototyping, July 24-28, 2019, Washington D.C., USA

by Massimo Di Nicolantonio,Emilio Rossi,Thomas Alexander

  • Publisher : Springer
  • Release : 2019-06-04
  • Pages : 671
  • ISBN : 303020216X
  • Language : En, Es, Fr & De
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This book discusses the latest advances in digital modeling systems (DMSs) and additive manufacturing (AM) technologies. It covers applications of networked technologies, ubiquitous computing, new materials and hybrid production systems, discussing how they are changing the processes of conception, modeling and production of products and systems of product. The book emphasizes ergonomic and sustainability issues, as well as timely topics such as DMSs and AM in Industry 4.0, DMSs and AM in developing countries, DMSs and AM in extreme environments, thus highlighting future trends and promising scenarios for further developing those technologies. Based on the AHFE 2019 International Conference on Additive Manufacturing, Modeling Systems and 3D Prototyping, held on July 24-28, 2019, in Washington D.C., USA, the book is intended as source of inspiration for researchers, engineers and stakeholders, and to foster interdisciplinary and international collaborations between them.

Cold Spray in the Realm of Additive Manufacturing

Cold Spray in the Realm of Additive Manufacturing
A Book

by Sunil Pathak,Gobinda C. Saha

  • Publisher : Springer Nature
  • Release : 2020-05-12
  • Pages : 245
  • ISBN : 3030427560
  • Language : En, Es, Fr & De
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This book sheds light on the development of the cold spray process in applications of additive manufacturing (AM) and repair/remanufacturing engineering. It covers the process fundamentals of different cold spray techniques, namely low pressure cold spray and high pressure cold spray process. Bonding mechanism and powder substrate interface are an important part of the book. The chapters present the recent developments in materials used in cold spraying for AM and various coating applications. The latest research in this area as well as possible avenues of future research are also highlighted as a way to encourage the researchers.

Repair of Metallic Components Using Hybrid Manufacturing

Repair of Metallic Components Using Hybrid Manufacturing
A Book

by Renwei Liu

  • Publisher : Unknown Publisher
  • Release : 2017
  • Pages : 115
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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"Many high-performance metal parts users extend the service of these damaged parts by employing repair technology. Hybrid manufacturing, which includes additive manufacturing (AM) and subtractive manufacturing, provides greater build capability, better accuracy, and surface finish for component repair. However, most repair processes still rely on manual operations, which are not satisfactory in terms of time, cost, reliability, and accuracy. This dissertation aims to improve the application of hybrid manufacturing for repairing metallic components by addressing the following three research topics. The first research topic is to investigate and develop an efficient best-fit and shape adaption algorithm for automating 3D models' the alignment and defect reconstruction. A multi-feature fitting algorithm and cross-section comparison method are developed. The second research topic is to develop a smooth toolpath generation method for laser metal deposition to improve the deposition quality for metallic component fabrication and repair. Smooth connections or transitions in toolpath planning are achieved to provide a constant feedrate and controllable deposition idle time for each single deposition pass. The third research topic is to develop an automated repair process could efficiently obtain the spatial information of a worn component for defect detection, alignment, and 3D scanning with the integration of stereo vision and laser displacement sensor. This dissertation investigated and developed key technologies to improve the efficiency, repair quality, precision, and automation for the repair of metallic components using hybrid manufacturing. Moreover, the research results of this dissertation can benefit a wide range of industries, such as additive manufacturing, manufacturing and measurement automation, and part inspection"--Abstract, page iv.