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<p>Hybrid additive manufacturing (AM) integrates distinct fabrication routes to reduce production costs and time while preserving design freedom. This work introduces a novel hybridization strategy that combines an indirect sinter-based AM process, namely material extrusion (MEX), with conventional manufacturing (CM) to produce integrated metallic components in 17-4PH stainless steel.&#xa0;The approach exploits the shrinkage of the MEX part during sintering to promote bonding with the conventionally manufactured counterpart. The bonding mechanism between MEX-fabricated hollow cylinders and conventionally manufactured rods of the same alloy was investigated. Hollow MEX cylinders were debinded and dried prior to inserting CM rods into their cavities, followed by sintering to induce shrinkage-driven consolidation at the interface. The hybrid parts were characterized using dimensional measurements, mechanical testing and microstructural observations. Hybridization increased the overall length and modified the external diameter near the upper region of the MEX zone. Mechanical tests revealed two distinct behaviors, with a maximum apparent adhesion strength of 39.8 ± 1.5&#xa0;MPa before decohesion. Depending on the local surface roughness, the interface exhibited both open and closed regions. Furthermore, hybridization reduced the inter-filament gaps in the vicinity of the MEX contours and decreased the size of sintering pores at the interface.</p>

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Integrating indirect additive and conventional manufacturing to produce hybrid metallic components

  • 期刊论文

  • 发表日期：

    2026年2月28日

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  • Mohamad Rostom,
  • Mahdi Chemkhi,
  • Léa Le Joncour,
  • Mahmoud Naim

摘要

Hybrid additive manufacturing (AM) integrates distinct fabrication routes to reduce production costs and time while preserving design freedom. This work introduces a novel hybridization strategy that combines an indirect sinter-based AM process, namely material extrusion (MEX), with conventional manufacturing (CM) to produce integrated metallic components in 17-4PH stainless steel. The approach exploits the shrinkage of the MEX part during sintering to promote bonding with the conventionally manufactured counterpart. The bonding mechanism between MEX-fabricated hollow cylinders and conventionally manufactured rods of the same alloy was investigated. Hollow MEX cylinders were debinded and dried prior to inserting CM rods into their cavities, followed by sintering to induce shrinkage-driven consolidation at the interface. The hybrid parts were characterized using dimensional measurements, mechanical testing and microstructural observations. Hybridization increased the overall length and modified the external diameter near the upper region of the MEX zone. Mechanical tests revealed two distinct behaviors, with a maximum apparent adhesion strength of 39.8 ± 1.5 MPa before decohesion. Depending on the local surface roughness, the interface exhibited both open and closed regions. Furthermore, hybridization reduced the inter-filament gaps in the vicinity of the MEX contours and decreased the size of sintering pores at the interface.