3D printing for ultra-precision machining: current status, opportunities, and future perspectives

Abstract Additive manufacturing, particularly 3D printing, has revolutionized the manufacturing industry by allowing the production of complex and intricate parts at a lower cost and with greater efficiency. However, 3D-printed parts frequently require post-processing or integration with other machining technologies to achieve the desired surface finish, accuracy, and mechanical properties. Ultra-precision machining (UPM) is a potential machining technology that addresses these challenges by enabling high surface quality, accuracy, and repeatability in 3D-printed components. This study provides an overview of the current state of UPM for 3D printing, including the current UPM and 3D printing stages, and the application of UPM to 3D printing. Following the presentation of current stage perspectives, this study presents a detailed discussion of the benefits of combining UPM with 3D printing and the opportunities for leveraging UPM on 3D printing or supporting each other. In particular, future opportunities focus on cutting tools manufactured via 3D printing for UPM, UPM of 3D-printed components for real-world applications, and post-machining of 3D-printed components. Finally, future prospects for integrating the two advanced manufacturing technologies into potential industries are discussed. This study concludes that UPM is a promising technology for 3D-printed components, exhibiting the potential to improve the functionality and performance of 3D-printed products in various applications. It also discusses how UPM and 3D printing can complement each other.