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Near-net shape manufacturing is transforming how industries approach production. By delivering components that are remarkably close to their final design, this methodology reduces waste, optimises efficiency, and creates new possibilities for cost-effective manufacturing. It has become an indispensable process in sectors such as aerospace, automotive, and healthcare, where precision and sustainability are key.
At its core, near-net shape manufacturing uses advanced techniques - such as casting, forging, or additive manufacturing - to produce parts that require only minimal finishing. This means less material waste, reduced energy consumption, and shorter production timelines compared to traditional methods. By aligning with lean manufacturing principles, near-net shape manufacturing supports businesses in their drive toward more sustainable practices.
The Role of Over-Thickness in Achieving Near-Net Shape
In metal additive manufacturing, over-thickness is a deliberate addition of extra material to ensure components meet their precise specifications after post-processing. This strategic adjustment accounts for factors such as shrinkage, distortion, or surface roughness during the production process.
Adding over-thickness ensures that the part can be machined or finished to the required tolerances. Whether it’s for assemblies, hybrid designs, or components with tight tolerances, the concept is integral to creating parts that meet stringent quality standards.
When and Where to Apply Over-Thickness
The need for over-thickness depends on the application and design of the part. Here are some common scenarios:
- Complex Geometries: For parts with intricate shapes, over-thickness helps compensate for shrinkage or distortion.
- Critical Tolerances: Tight tolerances demand precision, making over-thickness essential to achieving the final specifications.
- Selective Application: Hybrid designs or functional areas often require targeted over-thickness for assembly points, mating surfaces, or critical features.
Applications That Don’t Require Over-Thickness
In some cases, the printed part’s inherent design and shape are sufficient to meet functional needs without requiring additional material for post-processing. These include:
- Simple Designs: Parts with straightforward shapes and minimal features often experience little to no distortion during printing, eliminating the need for adjustments.
- Hollow Components: Parts such as those traditionally made from metal sheets or tubes may only need light surface polishing, if any post-processing at all.
- Low-Stress Applications: For components with non-functional or aesthetic purposes, where strength or precise tolerances are less critical, skipping over-thickness can save both time and material costs.
By considering these factors during the design phase, engineers can ensure that the final part meets its intended functionality while optimising material usage and cost.
How to Implement Over-Thickness
Applying over-thickness typically involves modifying the CAD design to include additional material in specific areas. Tools such as the offset, shell, or extrude functions in CAD software allow designers to refine geometries for optimal results. Although slicer software or scaling operations can also be used, these methods are less precise and not generally recommended for critical applications.
The amount of over-thickness added depends on the project requirements, material, and intended post-processing. For instance, a standard guideline for metal additive manufacturing recommends an additional 1.5 mm wherever high accuracy and low surface roughness are essential.
Why Near-Net Shape Manufacturing Stands Out
Near-net shape manufacturing distinguishes itself from traditional processes through its ability to reduce material waste and production time. Compared to techniques like forging, which can waste up to 80% of material, near-net shape minimises the need for extensive tooling and long lead times.
In contrast to methods such as Wire Arc Additive Manufacturing (WAAM), certain laser-based Directed Energy Deposition (DED) processes offer higher precision and finer control. This enables manufacturers to achieve detailed geometries with reduced thermal distortion and minimal shrinkage—significantly lowering the need for over-thickness.
Unveiling the Innovator Behind the Process
One company has pushed the boundaries of what’s possible with near-net shape manufacturing, integrating precision and cost-efficiency like never before. Their advanced laser DED technology combines high resolution, material efficiency, and versatility to deliver industry-leading results.
From aerospace to automotive, this solution has proven its value in producing parts with unmatched quality. The company behind this innovation? Meltio. With their unique Wire-Laser Metal Deposition (Wire-LMD) technology, Meltio is driving the evolution of near-net shape manufacturing, helping industries achieve more with less.
The workflow diagram illustrates the process of Meltio’s technology, describing two distinct paths based on the requirement for post-processing.
Connect with Mike, our Meltio Technical Manager, on LinkedIn