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<p>Hybrid Additive Manufacturing (HAM) represents an advanced and evolving manufacturing standard that combines additive manufacturing (AM) with either subtractive manufacturing (SM) techniques or with other AM processes to fabricate components with superior functional performance. This integrated approach influences the synergistic strengths of each process, such as the geometric flexibility of AM and the precision or surface finish capabilities of SM, or the material and functional synergies of multi-AM integrations to enhance the overall manufacturing outcome. The additive component, typically achieved through techniques like directed energy deposition (DED) and powder bed fusion (PBF), enables the creation of complex geometries. The subtractive process, often involving post-processing methods like milling, improves surface finish, dimensional accuracy, with enhanced material properties like tensile, fatigue strength and wear resistance. Laser-based HAM process combining the additive and subtractive methods allows for a precision of about 90% of the final product due to its controlled surface finish. This synergistic approach allows for the creation of components that transcend mere geometrical complexity, offering superior mechanical performance crucial for industrial applications. The enhanced tensile and fatigue strength achieved through these methods is highly desirable. Therefore, rigorous quality control measures are indispensable throughout these integrated processes, ensuring meticulous monitoring and optimization of parameters to guarantee the reliability and repeatability of the final products. This review study examines the opportunities and challenges involved in integrating additive and subtractive technologies, specifically considering their influence on mechanical properties and applicability across various industrial sectors. It addresses critical issues like material variability, maintaining process stability, and the necessity for sophisticated monitoring systems. The paper explores future advancements designed to boost the efficiency of this hybrid process, ultimately yielding high-performance materials with reduced waste.</p>

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A Review of the Quality Control and Mechanical Properties in Hybrid Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年9月9日

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  • Sazzad Hossain Emon,
  • Do Sik Shim

摘要

Hybrid Additive Manufacturing (HAM) represents an advanced and evolving manufacturing standard that combines additive manufacturing (AM) with either subtractive manufacturing (SM) techniques or with other AM processes to fabricate components with superior functional performance. This integrated approach influences the synergistic strengths of each process, such as the geometric flexibility of AM and the precision or surface finish capabilities of SM, or the material and functional synergies of multi-AM integrations to enhance the overall manufacturing outcome. The additive component, typically achieved through techniques like directed energy deposition (DED) and powder bed fusion (PBF), enables the creation of complex geometries. The subtractive process, often involving post-processing methods like milling, improves surface finish, dimensional accuracy, with enhanced material properties like tensile, fatigue strength and wear resistance. Laser-based HAM process combining the additive and subtractive methods allows for a precision of about 90% of the final product due to its controlled surface finish. This synergistic approach allows for the creation of components that transcend mere geometrical complexity, offering superior mechanical performance crucial for industrial applications. The enhanced tensile and fatigue strength achieved through these methods is highly desirable. Therefore, rigorous quality control measures are indispensable throughout these integrated processes, ensuring meticulous monitoring and optimization of parameters to guarantee the reliability and repeatability of the final products. This review study examines the opportunities and challenges involved in integrating additive and subtractive technologies, specifically considering their influence on mechanical properties and applicability across various industrial sectors. It addresses critical issues like material variability, maintaining process stability, and the necessity for sophisticated monitoring systems. The paper explores future advancements designed to boost the efficiency of this hybrid process, ultimately yielding high-performance materials with reduced waste.