In previous articles, we’ve discussed various machines and technologies that pertain to additive and subtractive machining. There have been significant advances in both arenas, but some of the most exciting innovations in manufacturing revolve around the combination of the two contrasting but complementary machining styles. This is known as hybrid manufacturing.
Hybrid manufacturing refers to processes that take advantage of both 3D printing operations (additive) and more commonplace mill/turn cutting operations (subtractive). The latest machine tools can actually perform all of these operations on the same piece of equipment, and in some cases can alternate between the two seamlessly.
Why use hybrid manufacturing
The benefits of hybrid manufacturing have to do with its streamlined process of producing a part. In the past, 3D printing and machining operations (mill/turn) would need to be performed on separate machines. This would require several different programs, setups, operators, etc. Depending on the part being produced, this could quickly turn into a complicated and time-consuming process.
In hybrid manufacturing, all of these printing/machining operations are executed on one machine. This significantly cuts down on time/costs associated with part setups. It also has the added benefit of reducing material waste and limiting potential errors that could occur when switching from machine to machine.
Examples of hybrid manufacturing in use
Today, there are many well-known companies that are utilizing hybrid manufacturing technologies. GE, for example, produces a contoured turbine blade on a hybrid machine capable of “printing” metal and performing 5-axis milling and full turning operations. This has significantly increased production efficiency and offers far more flexibility when it comes to design and engineering. Hybrid manufacturing is capable of producing parts with complex design elements that would otherwise be unachievable through standard machining operations.
EDAG, an engineering firm based in Germany is using hybrid machining to push the limits of design in manufacturing. Using additive metal manufacturing and three-dimensional laser welding, the company is able to design and fabricate custom “space frames” that can be optimized for a number of field-critical specifications. The hybrid process results in structures capable of meeting/supporting high load requirements, while at the same time minimizing frame weight through the use of additive manufacturing and 3D laser technology. These structures would not be reproducible through conventional manufacturing.
The future of hybrid manufacturing
In the years to come, we should expect to see increased adoption of hybrid manufacturing across a wide range of industries. The technology offers incredible advantages in terms of speed and productivity, especially when it comes to rapid prototyping. Hybrid manufacturing significantly shortens the length of time between conceptualization and production, and could thus help companies more quickly get new products to market.
When it comes to mass production, it may be too early to tell whether hybrid manufacturing will begin to replace more conventional methods. While it’s true that hybrid machines can save a great deal of time/money on setup and operation, they are far from cheap and companies will have to weigh the heavy price tag with their savings on production. Additive manufacturing also has a ways to go before it can rival its counterparts in terms of production speed, but we could see this gap close more in the years ahead.
In general, hybrid machining is an exciting subset of the manufacturing realm, and it will be fascinating to see how the technology is used in the future. For the right company, with the right product, hybrid manufacturing could be a game-changer when it comes to design, engineering and part production.