Additive manufacturing (AM) opens new possibilities of obtaining ceramic green parts with a tailored complex design at low cost. Meeting the requirements of highly demanding industries (aeronautical and biomedical, for example) is still challenging, even for machining. Hybrid machines can solve this problem by combining the advantages of both additive and subtractive processes. However, little information is currently available to determine the milling parameters of additively fabricated ceramic green parts. This article proposes a systematic approach to experimentally determine the cutting parameters of green AM zirconia parts. Three tools, one dedicated to thermoplastics, one to composites, and a universal tool, were tested. The tool–material couple standard (NF E 66-520-5) was followed. The lower cost and repeatable generation of smooth surfaces (Ra < 1.6 µm) without material pull-out were the main goals of the study. The universal tool showed few repeatable working points without material pull-out, while the two other tools gave satisfying results. The thermoplastic tool ensured repeatable results of Ra < 0.8 µm at a four times lower cost than the composite tool. Moreover, it exhibited a larger chip thickness range (from 0.003 mm to 0.036 mm). Nevertheless, it generated an uncut zone that must be considered when planning the milling operations.

The conventional design process (CDP) considers availability issues at the latest stages of the overall machine design project. Designers’ contributions are focused on technical and quality aspects. In most instances, other teams within the supply chain address delivery issues separately. Yet, current machine design projects are severely bound by deadlines, volatile, and sometimes uncertain. Due to the iterative nature of the design process itself, the number of potential design combinations is large. Their inherent technical checks and evaluations are highly time-consuming. In this paper, to avoid unnecessary design effort, the availability of components is considered at the early stages of the design process. This paper presents the Availability Based Design (ABD), which reorders the design process steps to preclude achieving a design that would be incompatible with the delivery time constraints. A ball screw drive actuator is used as a reference case study to quantitatively compare the performance of ABD to the CDP. The influence of key parameters is studied, including the availability ratio, the automation of key steps of the design process, the number of families of components and the number of technical checks necessary for validating a design. The performance assessment shows that ABD reduces the design time for availability ratios below 0.8 in manual design, and that automating the method makes ABD systematically faster than the CDP.