How Hybrid Machine Tools are Transforming Manufacturing

The hybrid additive manufacturing machine market is valued at 215.78 Bn USD in 2024 and is likely to reach a net valuation of 437.27 Bn USD by 2029 growing at a CAGR of 15.17 percent according to a report published by Mordor Intelligence . There has also been emergence of various new business entities using additive manufacturing and widespread technology adoption has also been done for legacy manufacturing systems. Additive manufacturing  technologies are being implemented with the help of hybrid machining tools that is slowly revolutionizing the manufacturing sector. The usage of these transformative technologies is not necessarily to lower the dependence on manpower but for process simplification.

On research, several instances appear in which hybridized machining systems are working wonders for the manufacturing sector.

Increased Capability in Cutting Tools

Additive manufacturing is bringing about newer possibilities in case of cutting tools for machining purposes. The possibilities can be applied to both big and small tools. In case of delicate precision cuttings, the passages for minute cross section drills do not need to be machined. The usage of 3D printing has made it simpler as the drills can now follow a carving path that is condusive of the flow of the coolant. In case of larger tools, 3D printed geometric forms are currently in use so as to reduce the mass of the component and combine it with polymer composite instead of metal for manufacturing the shaft of the tool. Put together, the process can deliver a weight savings of 40 to 50% on all heavy precision components.

E.g, both tools can be availed from Kennametal. The company’s KenTIP FS line of modular drills in sizes 10 mm in diameter and smaller are made additively through LPBF. There was no practical way to create internal passages by drills with such a small cross sections previously. With AM, the passages do not have to be machined now.  They can be easily grown inside as part of the 3D printing, and can follow a curving path that is conducive to efficient coolant flow.

Bringing Additive and Subtractive Manufacturing Together

Hybrid machining for manufacturing has become a revolutionary way to bring additive manufacturing and subtractive manufacturing together within a same machine. The integrated system will then have the the potential for production and repair of finished components inside the same piece of machinery. This process have been effective in reducing cost of materials used along with time efficiency. A manufacturer is able to achieve specificity in product and flexibility in production without switching machinery.

To give an example,  Autodesk and Phillips are now positive about their collaboration and are of the belief that their combined experience in the field will be able to encourage greater adoption in the AM segment.

 “Phillips Corp has been a Haas Factory Outlet for over 30 years with over 18,000 machines installed – this brings unrivalled experience in the industries they serve and reach to users as well as experience in the machine platform. Autodesk’s Fusion 360 has a rapidly growing user base amongst Haas users, offering a powerful, easy to use, integrated workflow from design to manufacture”, stated Robert Bowerman, Senior Technology Consultant, Autodesk. 

Increased Manufacturing Efficiency

Many legacy manufacturing organizations have adopted the most advanced form of hybrid addititive manufacturing processes in order to gain time efficiency with the helpof 3D printing technology. This is a kind of modification in engineering that has taken place over the decade which would have sounded impractical or cost-prohibitive in the past but now, using this technology 3D printing and machining could be completed in the same cycle.

To give an example, GE (General Electric) can be considered as one of the major manufacturing companies that is very closely associated with advance additive manufacturing (AM). The company has manufactured a fuel nozzle for its Leading Edge Aviation Propulsion (LEAP) jet engine serves as one of the finest examples in the field of AM adoption. The organization has also taken initiatives such building a Center for Additive Technology Advancement in Pittsburgh, Pennsylvania that promotes AM adoption all across the company. GE’s recent acquisitions of companies have made the company turn into a supplier of AM as well. However, an achievment that is noteworthy is related to AM came because of an additional acquisition. GE is the first production user of Hamuel’s additive and subtractive machining center for turbine blade repair.

Several technology innovations on the subject of hybrid additive manufacturing is taking place all across the world with many large corporations turning their heads towards this technology. We are also able to see the adoption of hybrid manufacturing processes in a developing country like India where it is making considerable impact on the injection molding industry and is poised for further developments in the years to come.