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Additive Manufacturing based on Powder Bed Fusion processes enables the construction of end-use functional metal components, making it feasible to design several level of geometrical complexity. Nevertheless, the printing process leads to material and shape defects, residual stress and induced distortions on final components that mainly are caused by the high thermal gradients associated to the intense and nonuniform power energy sources used to selectively melt metal powders. In this paper, techniques to reduce or prevent these effects are summarized. The more broadly Design for Additive Manufacturing approach based on the use on CAD platforms for product-process design is the backbone upon this research is based on. Specifically, the work presents a design method to predict drawbacks and improve the industrialization subphase. Laser-based Powder Bed Fusion technique is considered and the implementation and validation of the Selective Laser Melting process simulation is performed in order to support the method. Two case studies are presented. The former demonstrates the simulation implementation feasibility through a CAD platform. The latter validates the simulation results compared to experimental data for further method application.

In nearly every sector of industrial manufacturing, especially the mould and die making industry, polishing techniques are used. Most often, manual polishing is the only option because the tasks are too complex to be automated in terms of surface quality demands, geometrical features and restricted tool accessibility. Therefore, the European H2020 Project SYMPLEXITY “Symbiotic Human-Robot Solutions for Complex Surface Finishing Operations” developed a CNC-machine-based machining concept comprising a composition of different finishing technologies. The solution is complemented with an objective metrology surface qualification device, which is capable to also measure big parts holistically. The SYMPLEXITY approach combines both a collaborative, intelligence-based and a cooperative human-robot-based technological approach. The demonstrator machine concept is being introduced and first fine machining experiments, comprising polishing and measurements have been conducted to generate an initial parameter set-up. The experiments have been conducted on an empiric basis to identify the main steering parameters for a future semi -analytic, model-based finishing approach.