3D Printing and Beyond: Integrating AM with Traditional Processes for Next-Generation Products
Speaker: Dr. Amnon Shirizly
Abstract: The convergence of additive manufacturing (AM) with traditional manufacturing processes such as casting and metal forming presents a paradigm shift in the design and fabrication of high-performance components. This work explores hybrid process chains that leverage the geometric flexibility of AM, the scalability and material diversity of casting, and the mechanical enhancement capabilities of metal forming.
In this presentation we will present case studies demonstrating the integration of laser powder bed fusion (L-PBF) and/or directed energy deposition (DED) with investment casting and hot/cold forming techniques. These hybrid approaches enable the fabrication of components with complex internal geometries, functionally graded materials, and site-specific mechanical properties. Key challenges addressed include metallurgical bonding at process interfaces, residual stress management, and process parameter harmonization. Simulation-driven design methodologies and topology optimization are employed to exploit the full potential of these integrated processes. The results highlight significant improvements in weight reduction, structural integrity, and design freedom, with implications for aerospace, automotive, and energy applications.
About the speaker: Dr. Amnon Shirizly completed his PhD studies in Mechanical Engineering at the Technion in 1996, specializing in plastic deformation of metals. From 1997 to 1999 he conducted post‑doctoral research at the University of Waterloo in Canada. Since returning to Israel, he has been working at Rafael. In recent years he has served as a Research Fellow and CTO in the field of structural technologies, and is among the pioneers of 3D printing at Rafael.
In parallel, he teaches at the Technion, supervising and mentoring graduate students (Master’s and PhD) at the Technion and at Ben‑Gurion University. He also serves as the Chief Technologist of the Laminates Division (3D printing) at the Israel Engineers Association and is involved in organizing and leading activities and conferences in the field of additive manufacturing.