Hybrid Manufacturing Systems: Integrating Additive and Subtractive Techniques for Precision and Versatility

Hybrid manufacturing, combining additive and subtractive techniques, addresses the need for precision, efficiency, and flexibility in modern manufacturing. This study investigates the integration of these two approaches to overcome the limitations of standalone methods, particularly in achieving complex geometries and high-quality finishes. A comprehensive experimental framework was developed, utilizing both additive manufacturing (AM) for initial structure formation and subtractive manufacturing (SM) for refinement. Key findings indicate that the hybrid system reduced production time by up to 50% compared to traditional methods, achieved surface roughness improvements of 70%, and maintained dimensional accuracy within ± 0.5µm. Additionally, material utilization rates exceeded 95%, significantly minimizing waste. This research not only demonstrates the enhanced efficiency and precision of hybrid manufacturing but also introduces standardized protocols for process control and multi-material integration. These contributions suggest hybrid manufacturing as a promising solution for high-value industries such as aerospace and biomedical, while highlighting areas for further advancement in automation and energy efficiency.