The manufacturing world is disrupted by newer technologies and additive manufacturing is one of them. AM can make complex designs that are entirely not possible by traditional technologies (CNC, injection molding etc)at much lower costs, however, AM lacks the potential of mass production. Conventional manufacturing is not going to be entirely replaced by the AM due to certain advantages offered by CM like mass manufacturing at lower cost and high precision components. The fusion of additive manufacturing and conventional manufacturing can create a hybrid manufacturing system that can leverage the best of both technologies. Complementing each other, a hybrid manufacturing system has the potential to unlock new opportunities across the wider industrial spectrum. Hybrid manufacturing can create precision products that are complex in design and shape with reduced wastage and costs.

Hybrid manufacturing system

AM made parts are sometimes machined to attain tighter tolerances and surface finish according to the need and it’s a known industry-wide practice. If both technologies are combined, then it is known as a hybrid manufacturing system. It means the same machine contains both additive and subtractive manufacturing capability. Currently, a CNC machine carves out the shape from the metal block as per the CAD the data and the removed material is just a waste. For expensive materials like titanium, alloy steel etc. it's a costly waste. Hybrid manufacturing is most suitable for the short-run production of metal components. There are machines available in the market which contains both additive and CNC marching set-up. Existing CNC machines can be retrofitted with addon AM capability like a retrofit AM system provided by a company called Hybrid Manufacturing Technologies.

To leverage the strength of the hybrid system, the designer should design the part suitable for this kind of manufacturing set-up. Initially, the AM system creates the shape which is known as the near-net-shape and is later machined by the CNC to carve out the final shape close to dimensional accuracy followed by post-processing according to the requirement. Or initially, the part is CNC machined and then features are created by AM system which is again CNC machined to required dimensional tolerances.