A FRAMEWORK FOR ESTIMATING HYBRID MANUFACTURING COSTS

Based on its potential to reduce lead times, hybrid manufacturing, which often includes both additive manufacturing and machining processes, is receiving more attention from manufacturers as they seek to increase their supply chain resilience and efficiency. A new solid-state additive manufacturing method, referred to as additive friction stir deposition (AFSD), has shown the potential to become an important process for hybrid manufacturing. To justify the selection of a hybrid manufacturing approach, the cost needs to be estimated for comparison to conventional approaches. This thesis proposes a suite of cost models that include AFSD, powder bed fusion (PBF), wire arc additive manufacturing (WAAM), fused filament fabrication (FFF), structured light scanning (SLS), milling, and turning, which can be combined in hybrid manufacturing process planning. The cost models are applied to three case studies and cost estimates are compared for hybrid and conventional (machining-only) manufacturing approaches.