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<p>Fused Filament Fabrication (FFF) is widely used in Additive Manufacturing (AM) due to its low cost and ability to produce complex thermoplastic parts. Advances in high-performance materials, such as carbon fibre-reinforced PEKK, along with improved printer resolution have expanded its suitability for functional components. However, achieving high geometric precision remains challenging. Additive and Subtractive Hybrid Manufacturing (ASHM) offers a potential solution by combining 3D printing with subtractive post-processing, while a NURBS-based workflow can address geometric inaccuracies inherent to STL models. This study evaluates a NURBS-based Additive and Subtractive Hybrid Manufacturing (NURBS-ASHM) framework to fabricate cylindrical parts with high precision. Three methodologies were compared: conventional STL-based AM, precise AM using NURBS trajectories, and hybrid manufacturing integrating post-process milling. The results show that NURBS-based AM improves roundness and cylindricity by up to 49% and 43%, respectively, compared with STL-based printing, while ASHM further increases these gains to 73% and 78%. The proposed NURBS-ASHM framework is further extended to non-cylindrical geometries, particularly spherical surfaces, and to alternative machining processes such as turning, thereby confirming the applicability of the proposed framework to a wider range of operations and geometrical configurations. These findings demonstrate the effectiveness of integrating advanced modelling and hybrid processing as a general and transferable strategy for high-accuracy, cost-sensitive applications.</p>

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Additive and subtractive hybrid manufacturing strategy integrating a NURBS-based workflow for precision components

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年3月20日

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  • Jesús Miguel Chacón,
  • Javier Vallejo,
  • Eustaquio García-Plaza,
  • Pedro José Núñez,
  • Miguel Ángel Caminero

摘要

Fused Filament Fabrication (FFF) is widely used in Additive Manufacturing (AM) due to its low cost and ability to produce complex thermoplastic parts. Advances in high-performance materials, such as carbon fibre-reinforced PEKK, along with improved printer resolution have expanded its suitability for functional components. However, achieving high geometric precision remains challenging. Additive and Subtractive Hybrid Manufacturing (ASHM) offers a potential solution by combining 3D printing with subtractive post-processing, while a NURBS-based workflow can address geometric inaccuracies inherent to STL models. This study evaluates a NURBS-based Additive and Subtractive Hybrid Manufacturing (NURBS-ASHM) framework to fabricate cylindrical parts with high precision. Three methodologies were compared: conventional STL-based AM, precise AM using NURBS trajectories, and hybrid manufacturing integrating post-process milling. The results show that NURBS-based AM improves roundness and cylindricity by up to 49% and 43%, respectively, compared with STL-based printing, while ASHM further increases these gains to 73% and 78%. The proposed NURBS-ASHM framework is further extended to non-cylindrical geometries, particularly spherical surfaces, and to alternative machining processes such as turning, thereby confirming the applicability of the proposed framework to a wider range of operations and geometrical configurations. These findings demonstrate the effectiveness of integrating advanced modelling and hybrid processing as a general and transferable strategy for high-accuracy, cost-sensitive applications.