RECLAIM PROJECT
RECLAIM LASER CELL BOASTS ADDITIVE AND SUBTRACTIVE TECH FOR PART REPAIR
A laser cell that combines additive and subtractive machining methods for repairing components has been developed as the result of a project called Reclaim.Riccardo Tosi of the UK’s Manufacturing Technology Centre, who spoke about Reclaim at the Mach event in April, sets out the business case for building such a hybrid system
D
uring the past few years the use of lasers has become more popular thanks to cost savings and the high levels of quality, reliability, and handiness this
technology offers. Flexibility of choice is what the laser market can now offer; different lasers depending on application and end use. In September 2009, the Reclaim project,
supported by funding from the Technology Strategy Board (now called Innovate UK), started with the aim of ‘Remanufacturing high value products using a combined laser cladding, inspection and machining system’. Te result, developed by a consortium of
eight UK organisations, is a fully integrated remanufacturing cell designed for repairing high-value engineering products. Te system incorporates inspection and a 200W fibre laser for cladding, as well as high-speed machining in one cell, and is able to switch between processes automatically. It uses CAD/ CAM soſtware from Declam and a Sprint scanning head developed by Renishaw. Aſter three and half years of development,
the successful delivery of the project highlighted the possibility of combining subtractive and additive techniques inside a single hybrid cell. Since then, a build-up team that included
Hamuel, Hybrid Manufacturing Technologies (HMT), Delcam, and the Manufacturing Technology Centre (MTC) showcased the hybrid system at the EMO manufacturing show in 2014. Te idea was to demonstrate the use of hybrid technology – incorporating both additive and subtractive machining – and its
36 LASER SYSTEMS EUROPE ISSUE 31 • SUMMER 2016 The Reclaim cell can both remove and add material to repair parts
benefits. Removing and re-depositing material on a blade leading edge was shown during the exhibition; this helped visitors get a better understanding of the capability of the process, and allowed the end user and competitors to realise the potential of the new combined system. Te hybrid instrument launched at the show was awarded the EMO’s prestigious Best Multifunction Machine prize. A hybrid approach can support different
manufacturing and remanufacturing activities, such as adding new features, coating surfaces or renewing a damaged or worn area, using a combined additive plus subtractive solution. Numbers suggest that
companies are keen to extend the lifespan of their products, reducing costs and meeting the strict legislation agreed by countries in order to reduce emissions[1]
from several machine builders in developing a hybrid solution
. A
hybrid system can offer a flexible solution to change the approach to manufacturing challenges. Tere are more than half a dozen manufacturers offering a hybrid solution within their own machine portfolio. So what are the current limitations
I noticed an interest
preventing more widespread uptake of hybrid technology in the market? Te potential marketplace is enormous, especially considering the value of being able to regenerate a worn out part, resulting in significant environmental and financial benefits. Decreasing energy consumption and the use of raw material can support a reduction in manufacturing time and cost savings, which can be considered a profitable route to address legislation. In fact, a manufacturing design that considers end-of-life strategies is considered a higher quality product with more commercial viability[2]
. Where is the technology
at now and where can this market go? During the manufacturing event, Mach 2016, at the NEC in
Birmingham, UK, I saw several stands displaying hybrid systems, or where companies were claiming to have a hybrid solution under development. I noticed an interest from several machine builders in developing a hybrid solution in order to be part of the growing worldwide market, even if
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Manufacturing Technology Centre
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