GF Machining Solutions facilitates the manufacture of hybrid parts

In the manufacturing industry, different production methods are used depending on the type of part created. While additive manufacturing has proven its worth, whether for rapid prototyping or end-use part applications, it is still a method that is often complementary to subtractive manufacturing processes. Indeed, current technologies do not yet allow for the design of large volumes and are often too slow. Additive manufacturing is preferred for parts with very complex geometries, small series, prototyping or tooling. However, it can be seen that more and more manufacturers are looking to combine the two production processes: known as “hybrid manufacturing”, it offers a number of advantages and is, in some cases, more viable from an economic view point.

Nevertheless, combining these two processes can generate some challenges. In most cases, the part is 3D printed and then post-processed and machined to obtain the final geometry or a better surface finish. This is often the case for very complex components that incorporate internal geometries, such as cooling channels, or anything that cannot be machined directly from a metal block. These geometries require steps such as supports removal, heat treatment, milling or even manual polishing to achieve a better finish. These are often time-consuming and expensive and should be kept to a minimum.

Hybrid cutting tool | Image via GF Machining Solutions

Therefore, the hybrid manufacturing process has been increasingly employed to create these so-called “hybrid” parts. This process consists not only of combining additive and subtractive technologies, but more precisely of printing directly onto a conventionally pre-machined preform. Indeed, metal 3D printing is a process that can be time consuming and costly. Therefore, industrialists are able to machine their preform and then create or add, thanks to additive manufacturing, characteristics that would be impossible to obtain using conventional processes. The result: reduced production time, limited costs, and retained technological benefits.