HYBRID ADDITIVE AND SUBTRACTIVE MANUFACTURING PROCESSES

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Research

Research Projects ~7 Crores(~ $1.2 million)

  • Towards Sustainable Manufacturing at the Microscale: Addressing Some Scientific and Technological Issues,Swarnajayanti Fellowship, DST, Government of India, 3.0 Crores PI
  • In-situ Robotic Restoration System Based on Laser CladdingTechnology Systems Development, DST, 2.0 Crores, PI
  • Flexible Reconfigurable Fiber Laser Systems for Micro-scale Materials Processing, DST, Rs. 40 lakhs, PI
  • Engineered Surfaces on Pyrolytic Carbon for Bio-Medical Applications, CSIR, Rs. 20 lakhs, PI
  • Micro/Nano Technology Development, Nano-polishing of Semi-spherical Single Crystals and Arrayed Microstructure Fabrication by Excimer Laser LIGA, BARC, 66 lakhs, Co-Investigator (Nanopolishing)
  • Process development and modeling of novel EDM variants for Micromachining, DST, 27 lakhs, Co-PI
  • Generation of 3D Microscopic Hydro-phobic Geometries on Metallic surfaces sing Excimer (UV) lasers, ISRO-IITB Cell, 14.5 lakhs, Co-PI

Research Facilities (~3.5 Crores)

  • White light interferometry facility, IITB, 40 lakhs, PI
  • RIFC Grant of micromachining and micrometrology facility, IITB + NCAIR, 1.8 Crores, PII
  • 3-D optical profilometer, Center of Excellence in Steel Technology, Steel Ministry, 64 lakhs, PI
  • Wire-EDM of Si for photovltaic applications, NCPRE, Rs. 68 Lakhs, Co-PI

Facilities

High-Speed Micromachining Center

In house developed micromachining center
Micromilling / Microdrilling
High rotational speeds upto 140,000 RPM
High Accuracy and Precision
Vibration free and rigid structure
Machining of Hard-to-cut material
More information

Fiber Laser Center

100 W Single Mode Fiber Laser
Excimer Laser Micromachining Facility
Creation of 3D free form shape in wide range of materials

CNC Machine Center

DMG Mori-Seiki 5-axis Titanium Machining Center
Mikrotools CNC Micromachining Center
EMCO Precision CNC Lathe
Hardinge Vertical Machining Center
Wire and die-sink EDM

White Light Interferometer

Bruker Contour X200
Accurate surface topography
Sub-nanometer vertical resolution
2D & 3D non contact surface Metrology
More information
Operating Instruction

Surface Profilometer: Alicona

Optical 3D surface measurement device and a form measurement device
Form and roughness measurement
Measurement of materials with varying reflection properties
Measurement of areas and volumes in a vertical resolution of up to 10nm
More information

Surface Profilometer: Zeta Instruments

Non-contact 3D profiling and imaging device
Form and roughness measurement
Measure step height ranging from nm to mm
True Color 3D Imaging
More information

Alicona micro CMM

Non-contact 3D profiling and imaging device
Form and roughness measurement
Measure step height ranging from nm to mm
True Color 3D Imaging
More information

Wire EDM

High-accuracy machining of complex shapes
Superior surface finish and contour accuracy
Cuts materials ranging from delicate thin sections to thick components
Capable of processing hard and conductive materials with intricate details

Laser DED

Non-contact 3D printing and material deposition
Accurate form and surface reconstruction
Build and repair parts with material layers from microns to centimeters
Multi-material capability with true precision control

Formtracer

Accurate 2D and 3D form and roughness measurement
Capable of detailed surface contour and profile analysis
Measures heights and depths ranging from microns to millimeters
Delivers precise surface texture data for various materials
More information

Precision Instruments

Force Dynamometer: MiniDyn dynamometer
Laser Displacement Sensor
Acoustic Emission Sensing System
NI Data Acquisition System/High speed Digitizer

Computational Facilities

Deform 3D and 2D with Machining simulation modules
ABAQUS, ANSYS, Pro-Engineer
MATLAB and Simulink, COMSOL
Digimat - Multiscale Modeling
Dante – Heat treatment software
Composite modeler

Tool Maker Microscope

Precise, compact and easy-to-use measuring microscope for dimensioning and tolerancing
Geometrical measurement

Coordinate Measuring Machine (CMM)

Quality check and assurance
3D CAD model generation from product
More information

Micro Hardness Tester

Micro Hardness Testing of metals, composites and ceramics
A variety of selectable loads

Ph.D Students

Rajendra Hodgir

Topic:Powder based Laser-Directed Energy Deposition

Joining Year: 2020
Description:Focuses on simultaneously enhancing the build rate and quality of L-DED components through in-situ laser remelting.

Arvind Kumar

Topic: High Aspect Ratio Micro-Hole Drilling via Quasi-Continuous Waves Fiber Laser

Joining Year: 2021
Description: I’m working on improving high aspect ratio micro-holes in metals with QCW fiber laser drilling, focusing on reducing geometric imperfections (circularity, taper, humps, burrs) and metallurgical defects (recast layers, heat-affected zones, micro-cracks).

Suraj Kumar

Topic: Real time chatter dectection in high speed micromilling

Joining Year: 2021
Description: Working in real-time chatter detection and control in high-speed micromilling using signal processing and machine learning algorithm.

Shashank Shukla (Lab RA)

Topic: Additive Manufacturing of Advanced Materials

Joining Year: 2022
Description: Additive manufacturing of bulk metallic glasses and shape memory alloys via laser directed energy deposition technique for tribological, aerospace, marine, and smart technologies applications.

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Sutonu Oraon

Topic: Microscale-metal Wire Laser Directed Energy Deposition (MWL DED)

Joining Year: 2023
Description: Exploring the cutting-edge world of microscale metal wire Directed Energy Deposition (DED) with the help of Laser DED. Microscale laser DED technology transforms metal wire into intricate structures with unparalleled accuracy.

Rajesh Gorai

Topic:System Development and Characterization of Coaxial Wire Laser-Directed Energy Deposition Process

Joining Year: 2023
Description:Designing and optimizing the system Coaxial WLDED setup, including wire straightening, laser alignment, and automation with robotic control, this research aims to address challenges like thermal management, microstructural control, and process stability.

M.Tech

Md Selim Ahmed

Topic: Development of a Multi-Track Multi-Layer FEM model in LDED

Joining Year: 2022
Description: Development and investigation of thermal, thermo-mechanical and metallo-thermomechanical FEM to predict the defects and mitigate them by using laser re-melting technique for a Multi-Track Multi-Layer deposition.

Ameya Pevekar

Topic:TBD

Joining Year: 2023
Description:TBD

Lacky Kulhari

Topic:Integration of Cyber-Physical System & Digital Twin for Automated Repair.

Joining Year:2024

Mohit Jajoriya

Topic:In-situ laser scanning system development for restoration purposes.

Joining Year:2024

Jayendra Sharma

Topic:Design of Gripper for Modular-Head Docking System

Joining Year:2024

Lab Staff

Arun Nair

Designation: Senior Staff

Joining Year:2012

Naveen Dassari

Designation: Technical Supritendent

Joining Year: 2023

Sandeep Hiwale

Designation: Staff

Joining Year: 2010

Facility Booking

PLEASE SCAN THE QR CODE AND FILL THE FORM

BEFORE COMING TO THE LAB PLEASE FILL & BRING THE BELOW DOCUMENT WITH YOU

  • Form for external users of MTL Facilities
  • Form for internal users of MTL Facilities

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    Facility Charges:

    (Only for students and research institutes)

    (Industries may contact on official Email-ID)

    Facility

    Internal User (INR)

    External User (INR)

    		  
    Alicona Infinite Focus 300 580+104(18%GST)=684 Per Scan
    Bruker Alicona Micro CMM 500 780+140(18%GST)=920 Per Scan
    Zeta Microscope 250 460+82(18%GST)=542 Per Scan
    Bruker Contour WLI 250 460+82(18%GST)=542 Per Scan
    Rapid Eye Microscope 50 120+21(18%GST)=141 Per Scan
    Vicker's Microhardness Tester 100 240+43(18%GST)=283 Per Indent
    CMM 250 390+70(18%GST)=460 Per Geometry
    Micromachining Centers 500 1060+190(18%GST)=1250 Per Hour (Tools Extra)
    CNC Machines 400 820+147(18%GST)=967 Per Hour (Tools Extra)
    Wire EDMs 350 700+126(18%GST)=826 Per Hour

    Machine Tool Lab

    Mechanical Engineering Department
    IIT Bombay, Powai
    Mumbai -400076