Figure 1. Schematic diagram of the hybrid system at UMR

This paper presents the research and development of a hybrid rapid manufacturing process being developed at the University of Missouri-Rolla. This process includes a laser deposition and a 5-axis CNC milling system. By combining laser deposition and machining processes, the resulting hybrid process can provide greater build capability and better accuracy and surface finish. The hybrid process can build some features that are difficult to build in using a purely deposition processes. The issues and related approaches in the research and development of the hybrid deposition-machining process, including laser deposition process, system design and integration, process planning, and sensor selection and control, are discussed