Hybrid manufacturing of Invar mold for carbon fiber layup using structured light scanning

This paper describes coordinate system definition and transfer for five-axis machining of additively-manufactured preforms. In this method, a set of fiducials are attached to the temporarily attached to the part, and their location relative to the preform geometry is calibrated using a structured light scanner. Those fiducials can then be measured in the machine tool to determine the location and orientation of the part. The method is demonstrated by finish-machining a carbon fiber layup mold from an additively manufactured Invar preform. In addition to showing the coordinate transfer methods necessary to machine the part, several key challenges with machining additively-manufactured preforms are discussed and potential solutions are proposed. Unfortunately, the final part was ultimately unusable due to porosity inside the part left from the additive process. Future work will remanufacture this part while taking steps to avoid porosity and other challenges encountered.