A Study on Hybrid Manufacturing Systems Integrating Additive Manufacturing and CNC Machining for High-Precision Industrial Component Production

Abstract

This paper examines hybrid manufacturing systems that combine additive manufacturing and CNC machining for the production of high-precision industrial components. It focuses on architectures (in-process single-setup versus post-process multi-setup), machine configurations, material compatibility, and the process-physics factors that influence precision and surface finish. A benchmarking technique informed by literature is created, integrating standards-compliant language and inspection practices, and subsequently applied to specific part categories, including brackets, mold inserts with cooling channels, and nozzle-like precision channels. Quantitative data from primary studies indicate that hybridization can diminish geometric deviations from approximately 0.1 mm to around 10–20 μm on specific features, while facilitating sub-micrometer Ra through micro-milling and achieving approximately 1.5–2.5 μm Ra during in-process hybrid LPBF/milling within established wear limits. A sample cycle-time and cost model is shown using a timing example from a manufacturer datasheet and an open-access cost-model framework based on time-driven activity-based costing. There are suggestions for process planning (hybrid CAM), fixturing/registration, thermal/distortion control, and inspection procedures for polymer prototype materials, titanium alloys, aluminum alloys, and stainless steels.