Hybrid Manufacturing Overview

Hybrid Manufacturing is any combination of one or more manufacturing processes that are performed simultaneously (within the same setup/operational step)

Typically, most people when they refer to "Hybrid Manufacturing" are referring to Additive-Subtractive (+/-) Hybrid processes/systems, but other hybrid process exist:

• +/- Hybrid: Integration of additive manufacturing (3D printing) with subtractive (CNC machining) techniques.

• -/- Hybrid: Combination of multiple subtractive processes, for instance, waterjet or plasma cutting followed by precision milling or turning.

• Forming Hybrid: Inclusion of forming techniques such as stamping or bending with other manufacturing processes to exploit work hardening and grain refinement for improved material properties.

• Inspection, Assembly, etc.: Incorporation of real-time inspection, automated assembly, welding, and joining within the manufacturing sequence to streamline the production line.

The impetus behind hybrid manufacturing is the pursuit of excellence by combining the strengths of different manufacturing processes. By doing so, it aims to:

• Enhance Efficiency: Hybrid manufacturing optimizes production by reducing the need for multiple setups, decreasing handling time, and minimizing the lead time from design to finished product.

• Improve Quality: With integrated inspection and precision processes, hybrid systems can produce components with higher accuracy and better surface finishes than those produced by standalone processes.

• Increase Complexity and Functionality: It allows for the creation of complex geometries that are not feasible using traditional manufacturing methods alone, such as internal channels and lattice structures.

• Material and Cost Savings: The strategic layering and material removal steps reduce waste and conserve raw materials, leading to cost-effective manufacturing solutions.

• Customization and Flexibility: Hybrid systems can adapt to changes in design without the need for new tooling, supporting bespoke and small-batch production effectively.