Exploring Hybrid Manufacturing: Combining Additive and Subtractive Methods
- 77 Teknik
- Oct 19
- 3 min read
The Perfect Blend of Innovation, Accuracy, and Flexibility
Manufacturing technology is evolving beyond the limitations of purely additive or subtractive methods.The emerging solution, hybrid manufacturing, integrates 3D printing and CNC machining into one seamless workflow, delivering precision, efficiency, and design freedom never before possible.
At 77 Teknik, we harness hybrid manufacturing to achieve high accuracy parts, shorter lead times, and optimized material use for demanding applications in automotive, defense, and industrial sectors.
What Is Hybrid Manufacturing?
Hybrid manufacturing is an innovative production approach that seamlessly integrates additive manufacturing (AM), the process of building parts layer by layer, as in 3D printing, with subtractive manufacturing (SM), such as CNC machining, where material is precisely removed to achieve high tolerances and refined surfaces. By combining the strengths of both techniques, hybrid manufacturing creates a versatile, efficient, and precise production process that surpasses the limitations of traditional manufacturing methods.
This powerful fusion enables manufacturers to:
Create complex geometries: AM allows for intricate designs, such as lightweight lattice structures or internal channels, that are impossible or impractical with conventional methods like casting or milling alone.
Efficiently repair or modify parts: Hybrid systems can add material to worn or damaged components (e.g., aerospace turbine blades) and then machine them to restore precise specifications, extending part lifespans.
Achieve exceptional precision and surface quality: SM refines AM built parts to meet tight dimensional tolerances and deliver smooth, high quality surface finishes critical for industries like aerospace, medical, and automotive.
Minimize waste and optimize production time: AM reduces material usage by building only what’s needed, while SM ensures accuracy in fewer steps, streamlining workflows and cutting costs.
How Hybrid Manufacturing Works
The process typically follows a digital workflow:
CAD Design & Simulation
Engineers create a 3D model using CAD software.
Virtual simulations test mechanical properties, tool paths, and material behavior.
Additive Build Phase
Material (metal powder, filament, or resin) is deposited layer by layer.
This stage forms the rough geometry or internal features.
Subtractive Finishing
CNC machining refines surfaces, bores, and interfaces to meet exact specifications.
Real time sensors monitor tool wear and dimensional accuracy.
Quality Verification
Advanced CMM and laser scanning validate the final dimensions.
Advantages of Hybrid Manufacturing
Design Freedom – Complex internal channels, lattice structures, or lightweight geometries.
Precision Finishing – Tight tolerances and smooth surface quality with CNC finishing.
Reduced Lead Time – Fewer setups, faster prototyping, and direct digital workflows.
Sustainability – Minimal waste compared to traditional machining.
Repair Capability – Add material only where needed to restore worn or damaged parts.
Challenges:
Requires sophisticated equipment and software to integrate AM and SM seamlessly.
Demands skilled operators to manage complex workflows.
Higher initial investment compared to traditional single-process machines.
77 Teknik’s Hybrid Manufacturing Expertise
At 77 Teknik, we integrate hybrid manufacturing across our precision production capabilities:
Application Area | How We Apply Hybrid Manufacturing |
Aviation Components | Lightweight, high strength parts with internal cooling channels |
Machine Parts | Repair and optimization of complex mechanical assemblies |
Automotive Parts | Rapid design validation with functional testing |
Tooling & Fixtures | On demand repair and modification of high value tools |
Through CAD/CAM integration, simulation driven design, and multi axis CNC precision, we deliver production ready hybrid solutions that balance innovation and performance.
The Future of Hybrid Manufacturing
Hybrid systems are redefining production by bridging the gap between prototyping and full-scale manufacturing.As machine technologies evolve, expect more automated transitions between additive and subtractive steps, supported by AI-based optimization and digital twins.
At 77 Teknik, we continue to push these frontiers, combining engineering know how, digital manufacturing tools, and production flexibility to help clients achieve the next level of efficiency.
Let’s Build Smarter Together
Want to explore how hybrid manufacturing can enhance your production capabilities?
Contact 77 Teknik to discuss customized hybrid manufacturing solutions for your next project.