Hybrid Additive-Subtractive Manufacturing for High-Precision Tooling Applications: A Synergistic Approach to Surface Quality and Dimensional Accuracy

Abstract

Hybrid additive-subtractive manufacturing merges the design flexibility of additive manufacturing (AM) with the precision of subtractive processes such as CNC machining. This paper explores the synergistic integration of metal 3D printing and CNC milling to overcome limitations of standalone techniques in producing high-precision tooling components. The study discusses system integration, tool path planning, material compatibility, and process parameters critical to achieving superior surface finishes and tight dimensional tolerances. Through experimental case studies and comparative analysis, this work establishes best practices for hybrid manufacturing in tooling applications and proposes optimization strategies for achieving production-level quality and efficiency.

Keywords: Hybrid manufacturing, additive-subtractive process, metal AM, CNC machining, surface roughness, dimensional accuracy, tool path optimization, precision tooling