5553 Hybrid Manufacturing for Rapid Tooling and Repair – Phase 2

Examples of tooling repaired with additive manufacturing


When tooling components wear or break, they must frequently be replaced at a high cost and long lead time. The combination of additive and subtractive processes in the same machine has the opportunity to repair various types of tooling needed by both the defense and domestic manufacturing sectors. The technology and equipment, however, are still relatively new and untested. There is a need to explore, develop, and quantify the capabilities of hybrid repair manufacturing in industry-relevant applications.


Building off of the work in Phase 1 (Project 5524), the team will develop the hardware and software tools required to repair tooling components using a hybrid manufacturing process. These tools will be demonstrated on real-world tooling components solicited from the industry. Additionally, the team seeks to establish integrated control of the hybrid process to identify, predict, and compensate for distortion and material/mechanical non-uniformity during the repair process.

Technical Approach

Youngstown State University (YSU), Georgia Institute of Technology (GT), University of Texas at El Paso (UTEP), and Oak Ridge National Laboratory (ORNL) Manufacturing Demonstration Facility (MDF) are developing process parameters and tool path strategies for repair applications. Automation of as much of the process as possible will be explored. The Youngstown Business Incubator (YBI) is soliciting tooling repair candidates from the industry advisory group established in Phase 1. The team will down-select from this list to identify the repair opportunities best suited to the equipment being used. YSU, GT, UTEP, and ORNL will demonstrate their developed repair methodologies on the selected tooling components, which will then be provided back to the industry partners for usage and evaluation. Based on their feedback, as well as information gathered from the team repairing the components, YBI will construct a business case for using hybrid technology for tooling repair. In addition, teams at both UTEP and ORNL are developing modeling and in-situ process monitoring (ISPM) algorithms to inform the build process and improve final part quality and performance.

Project Participants

Project Principal

Other Project Participants

  • Georgia Institute of Technology
  • Oak Ridge National Laboratory
  • University of Texas at El Paso
  • Youngstown Business Incubator
  • Youngstown State University

Public Participants

  • U.S. Department of Defense

Project Summary

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