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(CST, Youngstown, Ohio, U.S.) operates a large-scale hybrid polymer manufacturing machine with a build volume of 8 × 12 × 24 ft. The company has development a fully integrated advanced manufacturing confluence (AMC) system that incorporates additive manufacturing, in-situ geometric scanning and machining capabilities all within one machine. According to CST, this enables rapid production and quality assessments of sophisticated, massive-scale, high-value products of interest to the Department of Defense (DOD) and non-DOD customers. Having a single platform eliminates the need for intermediate steps, making the overall process more cost-effective and the lead times shorter, according to the company. The AMC system provides a comprehensive process flow from customer requirements, through design to final part shipment.

CST also uses a model-based definition (MBD) approach throughout the AMC process. The digital MBD approach enables an authoritative digital definition of a product in the 3D master model that drives the additive/subtractive manufacturing processes of the AMC system and provides the baseline for the in-situ, 3D laser scanned, “as-manufactured” digital twin. Advanced simulation tools are an integral part of the MBD approach that help predict material behavior during processing, and custom, closed-loop systems developed in-house offer seamless operation ensuring the highest product quality. CST has the capability of producing parts for various applications demanding high performance in a rapid development environment, highlighting the advantages of the AMC process over conventional manufacturing approaches.  

Moreover, CST’s ability to establish catalog materials specific to large-format additive manufacturing and evaluate these polymers with an emphasis on final product material response enables significant reduction in process development cycles.

CST will feature customer/example parts and tooling for various applications at its CAMX booth. Product display ranges from free-formed geometries to performance-enhancing applications such as composite tooling produced by different materials.

CST’s efforts toward developing a digital twin for large-scale polymer additive manufacturing will be presented in poster format.