Hybrid manufacturing basically combine different technologies to overcome the shortcomings of individual manufacturing methods. In this presentation the additive manufacturing and its classification is explained. Then introduction of hybrid (additive + subtractive) manufacturing and its requirement is explained with classification, advantages, applications and present catastasis.

1. HYBRID METAL
ADDITIVE
MANUFACTURING
By –
Vishista Kaushik
M.Tech. (Production Engineering)
Astate– of–the –art review

2. CONTENT
 Introduction
 Metal Additive Manufacturing
 Hybrid Manufacturing
 Metal HAM with multiple thermal energy sources
 Metal HAM with forming processes
 Metal HAM with material removal processes
 Advantages of Hybrid Manufacturing
 Case Study
 Present Catastasis
 Conclusion
 References

3. Introduction
 Hybrid manufacturing = Additive manufacturing +
Subtractive manufacturing
 Why ?
All in one and simplified
 We will discuss :
MAM
HM
MHAM
[ https://amfg.ai/2018/07/10/hybrid-technology-the-future-of-manufacturing/ ]

4. Metal additive
manufacturing
Early 1980’s Kodama
SLA and FDM
Also known as rapid
prototyping.
Another name three
dimensional (3D) printing
[ File:///EI/Mtech/2%20sem/presentation/Anotomyatala_2011_715.mp4 ]

5. Classification of Additive Manufacturing
[4]

6. Hybrid Manufacturing
 A narrow definition of hybrid manufacturing based on
the previous definition requiring different process
mechanisms to be used in the same processing zone;
 An open definition of hybrid manufacturing based on
the combination of two or more established
manufacturing processes into a new combined set-up.
[ https://amfg.ai/2018/07/10/hybrid-technology-the-future-of-manufacturing/ ]

7. Classification of Hybrid Manufacturing
[4]

8. Metal HAM with multiple thermal
energy sources
 Belongs to the group I.A shown in last slide (assisted
processes)
 Overcome the limitation of laser welding
 Increase process stability

9. Metal HAM with forming processes
 Integration with processes to improve the properties of
the deposited metals
 Integration with bulk forming processes
 Integration with sheet forming processes
 Integration with joining by forming processes
[ https://www.sciencedirect.com/science/article/pii/S2666912921000027 ] [3]

10. Metal HAM with material removal
processes
 Grouped into two different categories:
 (a) Utilization of material removal processes at post-
processing level in order to obtain the geometry
precision, the dimensional tolerances and the surface
quality required for the built part;
 (b) Integration of material removal processes during a
manufacturing sequence to obtain parts that would be
impossible, to produce individually either by additive
manufacturing or by material removal operations.

11. Metal HAM with material
removal processes
[ https://www.sciencedirect.com/science/article/pii/S2666912921000027 ]
[4]

12. Advantages of Hybrid
Manufacturing
 Lowers AM acquisition cost
 Reduces operator learning time
 Enables net shape 3D printed metal parts
 Accommodates unique part sizes
 Speeds production of complex metal parts
 Enables increased machine tool utilization for repair,
coating, re-manufacturing

13. Case Study :
A feasibility study on additive manufactured
hybrid metal / composite shock absorbers
◦ This study demonstrated the effectiveness of the
proposed lightweight hybrid configuration based on
additive manufacturing techniques in terms of mass
reduction, mechanical and energy absorption
performances.
[5]

14. Application
 Production
 Medical
 Clothing
 Jewelry
 Food
 Automobile
 Aerospace
 Household accessories, etc,.
[ https://amfg.ai/2018/07/10/hybrid-technology-the-future-of-manufacturing/ ]

15. Present Catastasis
Hybrid Manufacturing Companies :
 DMG Mori
 Mazak
 Hermle
 Siemens
 Matsuura
 3D – Hybrid
 Fabrisonic
 Hybrid Manufacturing Technologies
 Optomec
 Sodick

16. Conclusion
Fulfils the important two-fold objective of:
(i) increasing the applicability domain
and overcoming the limitations of additive
manufacturing and
(ii) adding flexibility and fostering new
applications with traditional manufacturing
processes.

17. References
1) Kodama, H., 1981. Automatic method for fabricating a
three-dimensional plastic model with photo-hardening
polymer. Rev. Sci. Instrum. 52 (11), 1770–1773.
2) Lauwers, B., Klocke, F., Klink, A., Tekkaya, A.E.,
Neugebauer, R., Mcintosh, D., 2014. Hybrid processes
in manufacturing. CIRP Annals 63 (2), 561–583.
3) Meiners, F., Ihne, J., Jürgens, P., Hemes, S., Mathes,
M., Sizova, I., Bambach, M., Hamar- Saleh, R.,
Weisheit, A., 2020. New hybrid manufacturing routes
combining forging and additive manufacturing to
efficiently produce high performance components from
Ti-6Al-4V. Procedia Manufacturing 47, 261–267.

18. 4) Pragana J.P.M., Samapalo R.F.V., Braganca I.M.F.,
Silva C.M.A., Martins P.A.F., 2021. Hybrid metal
additive manufacturing: A state-of-the-art review.
Advances in Industrial and Manufacturing Engineering
2 (2021): 100032, 2666-9129
5) Valerio A., Salvatore S., Russo A., Ricco A. , 2021. A
feasibility study on additive manufactured hybrid metal
/ composite shock absorbers. Composite Structures,
Volume 268, 2021:113958
6) Zhu, Z., Dhokia, V.G., Nassehi, A., Newman, S.T.,
2013. A review of hybrid manufacturing processes–
state of the art and future perspectives. Int. J. Comput.
Integrated Manuf. 26 (7), 596–615.