International Journal of Mechatronics and Manufacturing Technology ISSN: 3139-5058 (Online)

Authors: Shyam Diwaker, Manisha Kulkarni, Deepak Bansal

Abstract: Additive Manufacturing (AM) has emerged as an important manufacturing technology in recent decades. Unlike traditional subtractive manufacturing where material is removed from a solid block, additive manufacturing builds components layer by layer using digital models. This approach enables the fabrication of complex geometries, lightweight structures and customized products which are difficult to produce using conventional machining methods. However, AM processes often suffer from limitations such as poor surface finish, dimensional inaccuracies, and lower mechanical properties in some materials. To overcome these issues, hybrid additive–subtractive manufacturing systems have been developed. These systems integrate additive manufacturing processes with traditional subtractive machining operations such as milling or turning within a single machine platform. Hybrid systems combine the advantages of both techniques, allowing near-net shape production using additive methods followed by precision finishing using machining operations. This paper reviews the principles of additive manufacturing, major AM technologies, and the concept of hybrid additive–subtractive systems. The advantages, challenges, industrial applications and future research directions are also discussed. The study shows that hybrid manufacturing systems are gaining increasing attention in aerospace, medical and tooling industries due to their ability to produce high precision complex components with reduced manufacturing time. Even though the technology is still developing, hybrid manufacturing is expected to play a significant role in the future smart manufacturing environment.

Keywords: Additive Manufacturing, Hybrid Manufacturing, Subtractive Machining, 3D Printing, Smart Manufacturing