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A Review of Hybrid Manufacturing: Integrating Subtractive and Additive Manufacturing
Bruno Freitas1, Vipin Richhariya1, Mariana Silva1
1Center for MicroElectroMechanical Systems (CMEMS-Uminho), University of Minho, 4800-058 Guimarães, Portugal.
Materials (Basel, Switzerland)
|September 27, 2025
Summary
Hybrid manufacturing (HM) integrates multiple processes like additive and subtractive manufacturing for complex parts. This review details laser-based HM setups, materials, and parameters to improve efficiency and material use.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Mechanical Engineering
Background:
- Traditional manufacturing struggles with complex geometries and surface characteristics, requiring multiple steps and transport.
- These limitations are particularly significant in micro and nano-scale product manufacturing.
- Hybrid manufacturing (HM) offers a solution by integrating multiple processes into a single setup.
Purpose of the Study:
- To provide a comprehensive overview of laser-based hybrid manufacturing (HM) machines and setups.
- To analyze HM based on machine axes, materials, and processing parameters.
- To highlight the potential of HM for efficient and accurate production of complex components.
Main Methods:
- Review of scientific literature and industry practices concerning hybrid manufacturing.
- Categorization of hybrid manufacturing setups based on machine configuration, materials processed, and operational parameters.
- Focus on laser-based additive and subtractive manufacturing integration.
Main Results:
- Identified various laser-based hybrid manufacturing setups utilized in research and industry.
- Detailed the types of machines, materials, and processing parameters relevant to HM.
- Highlighted the advantages of HM, including increased efficiency, accuracy, and reduced part transportation.
Conclusions:
- Hybrid manufacturing, particularly laser-based systems, presents a promising approach for producing complex and customized components.
- Further integration of sensors and artificial intelligence is needed for real-time adaptive manufacturing capabilities.
- This review offers valuable insights for optimizing HM processes for improved material utilization and productivity.
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