Hybrid Manufacturing

Hybrid Manufacturing: Hybrid manufacturing (HM), combining the capabilities of different manufacturing processes, has emerged as a powerful approach to leverage the strengths of each technique. Hybrid manufacturing allows for unprecedented design freedom, enabling the creation of intricate and complex geometries that are challenging with traditional manufacturing methods alone.  An instance of hybrid manufacturing technique that can be achieved involves integrating 3D printing with conventional manufacturing (CM). This innovative approach combines the design flexibility and complexity of 3D printing with the versatility of conventional manufacturing, offering unique advantages in creating intricate and functional metal objects. Recently, additive manufacturing (AM) has revolutionized the manufacturing industry by offering greater design freedom and customization capabilities. Unlike subtractive manufacturing, where materials are carved or machined to create the desired shape, additive manufacturing builds objects layer by layer, adding material only where it is needed. One of the key advantages of additive manufacturing is its ability to create complex geometries that are challenging or even impossible to achieve using traditional manufacturing techniques. This enables the production of highly customized and intricate designs, making additive manufacturing particularly valuable in industries where product customization, rapid prototyping, and small production runs are essential. 

By addressing these research goals, this study aims to advance the understanding and application of hybrid manufacturing using 3D printing and conventional manufacturing (CM), leading to improved processes, materials, and design strategies to produce lightweight components with enhanced performance and functionality. The main objectives of this research can be summarized as follows: 

1. To evaluate the feasibility of 3D printing assisted CM as a lightweight and complex component manufacturing process 

2. To investigate the feasibility of multi-materials lightweight and complex component manufacturing process using proposed hybrid manufacturing method 

3. To assess the mechanical properties and performance of lightweight components produced through HM, and 

4. To propose optimized design guidelines for lightweight and complex shape components.