Hybrid Solid State Additive Manufacturing: An Overview

Hybrid Solid State Additive Manufacturing (HSSAM) is an emerging manufacturing technology that combines multiple additive manufacturing processes with traditional subtractive machining methods. This approach offers unique advantages in terms of material flexibility, part complexity, and production efficiency. In HSSAM, a combination of different additive manufacturing techniques, such as powder bed fusion, directed energy deposition, or material extrusion, is employed to build up a near-net-shape part, which is then machined using subtractive methods to achieve the final dimensions and surface finish. This integration of additive and subtractive processes provides enhanced control over part quality, geometric accuracy, and material properties. HSSAM has found applications in various industries, including aerospace, automotive, and medical, where the ability to produce complex components with high precision and improved mechanical properties is essential. This paper provides an overview of the HSSAM process, including the different techniques involved, the benefits and limitations of the approach, and its applications in different sectors. It also discusses the future prospects and research directions in HSSAM, highlighting the potential for process optimization, material development, and advanced control strategies to further enhance the capabilities and expand the application range of this hybrid manufacturing approach