Industrial 3D printing technologies (commonly known as additive manufacturing technologies) have evolved in recent years, spurring greater adoption of industrial 3D printers and hybrid manufacturing machines for production. These machines offer manufacturing companies several advantages as well as an edge in an increasingly competitive market.
In the industrial sector, metal additive manufacturing (metal-AM) systems allow manufacturing companies to reliably create products from the ground up on a commercial scale. Industrial applications utilize many types of metal-AM, but metal-laser powder fusion (M-LPBF), also known as direct metal laser sintering (DMLS), has emerged as the most mature technology over the last 30 years. Hybrid machines are relatively new and combine additive and subtractive manufacturing technologies.
While these machines have some overlapping capabilities, there are different use cases and considerations for manufacturers looking to implement additive manufacturing technologies. Comparing metal-AM and hybrid manufacturing highlights the strengths of these machines and their adaptability to meet different manufacturers’ needs.
Industrial 3D Printers
Industrial 3D printers, such as DMLS systems, offer manufacturers more flexibility in both product designs and operational processes. Phillips Corporation, a company that partners with multiple industrial 3D printing product lines, such as EOS, has been helping manufacturers realize the benefits of additive technologies for years.
There are several differences when comparing consumer 3D printers to industrial AM platforms. For example: “In the industrial sector, the differentiator for 3D printers is that manufacturers require a level of reliability and repeatability from these machines that is suitable for commercial manufacturing, to produce full-strength end-use parts,” explains Tommy Lynch, senior applications engineer for additive manufacturing at Phillips Corporation.
Lynch has been in the additive manufacturing industry for over 20 years and has seen firsthand the growth of industrial 3D printing. In the early 2000’s industrial printing catered to prototyping and product development, primarily with polymers. Today, technology has evolved with metal-AM being used to manufacture everything from combustion chambers for rockets to medical implants to full-strength industrial tooling.
“These machines are geared toward printing hundreds or thousands of parts within days,” Lynch says. “The latest generation of metal-AM platforms are designed to give manufacturers the highest level of productivity possible, with minimal operator intervention.”
Manufacturers get many benefits from using metal-AM, including design flexibility, simplified production, reduced material waste, and the ability to prototype and manufacture on the same machine. Lynch highlights that it’s often economically advantageous for manufacturers to have 3D printing capabilities in-house, enabling facilities to achieve some cost-cutting initiatives and providing a reliable supply chain amid potential disruptions.
Expanding on that point, Lynch adds: “Industrial 3D printing may not always be the most cost-effective way to manufacture some parts, but it can offer significant time savings, which has immense value in a competitive market and allows manufacturers to be prepared for the unexpected.”
Hybrid Manufacturing Machines
Hybrid manufacturing combines additive and subtractive processes within one machine. This allows manufacturers to 3D print and machine a component without switching between machines.
Alex Potts, sales manager of the Hybrid division at Phillips Corporation, describes Phillips’ hybrid machines in more detail: “In our case, hybrid integrates subtractive CNC processes with directed energy deposition (DED) additive processes, including wire arc, laser-wire, or laser-powder DED, all in one platform.”
Potts explains that Phillips Additive Hybrid machines are often used to manufacture larger parts, with size limitations dictated by the size of the Haas CNC machine. “Hybrid machines enable manufacturers to create much larger parts on larger CNC platforms, and with technological developments like our 2-stage wire arc deployment mechanism, we are able to minimize the offset between machining spindle and welding arm to maximize the printing volume within the CNC machine,” he says.
Utilizing hybrid manufacturing machines enables manufacturers to reduce production time and increase manufacturing capability. Manufacturers can achieve significant time savings with hybrid machines, eliminating the need to have machinists move parts and adjust programming multiple times to create one product.
“With hybrid, you can reliably program a part from start to finish and get an end-use part directly from the hybrid machine,” says Potts. “With the ability to program both additive and subtractive processes in one file, manufacturers can achieve part geometries that could never be replicated through strictly subtractive manufacturing methods.”
Differences and Applications
When comparing DMLS and hybrid manufacturing technologies, industrial companies will find there are a lot of similar applications. Manufacturers will start to notice differences when it comes to the size, volume, and quantity of parts they need to create.
For example, a part that is 8 to 10 inches could easily be printed on both a hybrid or a DMLS machine, but the DMLS part will have superior surface finish and smaller feature resolution as printed. However, if the part exceeds 12 inches, hybrid manufacturing may be best because of the high deposition rate (resulting in faster build time), and the ability to machine the part to the desired surface finish.
“Oftentimes manufacturers can print a part on a hybrid machine or a DMLS machine,” Potts says. “At Phillips, it’s common that we review customer part files and perform a time study to evaluate which technology best fits their needs. If the majority of the part needs a machined surface, hybrid is usually the ideal choice. Material can also dictate which AM technology is best for a particular process, as some hybrid and DMLS technologies have limitations on the materials they can process, and customers may have a preference for using powder or wire feedstock.”
Applications for hybrid manufacturing machines include casting replacement, rapid prototyping, cladding, and repairing molds. The ability to perform these tasks in-house gives manufacturers more flexibility, reduces lead time, minimizes waste, and cuts down on costs.Some of these use cases are also applicable to DMLS technology but may be better suited to hybrid machines when a part needs to go through both additive and subtractive manufacturing methods. Applications that are well-suited for DMLS include assembly consolidation, new product development, product lightweighting, and quick design and production turnaround.
“The choice between these two machines depends on the unique challenges that a manufacturer is facing,” Lynch says. “Whether that’s cost, lead time, or a fragile supply chain.”
Both hybrid and DMLS printers have a number of use cases in multiple manufacturing industries — medical, automotive, and aerospace tend to be early adopters of these technologies, but they have made their way into many more (defense, electronics, agriculture, etc.). Though it will ultimately depend on the manufacturer’s needs, having access to additive capabilities through hybrid manufacturing or DMLS enables companies to be more competitive and flexible in their operations.
The Future of Industrial 3D Printing and Hybrid Manufacturing
While industrial 3D printing and hybrid manufacturing lend themselves to different applications, both technologies are continuing to grow and become more widely adopted by manufacturers. As more companies realize the benefits of additive manufacturing, these machines will have a greater presence in industry.
One opportunity for growth — shared by both Potts and Lynch — is to have additive technologies in technical programs and universities. “Additive isn’t just a different technology; it’s a different style of thinking,” says Potts. “If students are learning CNC and additive together, now we have a new generation thinking about how to make parts in a way that hasn’t been done before.”
“Universities now are graduating new design engineers who have been using 3D printers as part of their core curriculum, so additive is top of mind for them when solving a manufacturing challenge,” Lynch adds. “The technology has become a staple at almost any university that has a manufacturing or engineering program.”
Additive is becoming ingrained in manufacturing, and its rate of adoption is increasing. A couple of decades ago 3D printing was an emerging niche technology, and today it’s used regularly for everything from prototyping to production. And innovation in additive manufacturing is only going to continue from here.
“As features and options improve, the technology will offer more. And as the software evolves, machine usability will get easier,” says Potts. “It’s going to become a core knowledge for those in the manufacturing world, and this new way of thinking will help companies cut costs, save time, and be more efficient than we ever would have imagined.”
In the next five to 15 years, manufacturers can expect an additive manufacturing boom in the industry. If you’re a manufacturer looking to explore how your company can adopt additive technologies, learn more about the offerings at Phillips Corporation.
For more opportunities to explore innovative additive technologies, attend RAPID + TCT. Taking place in Detroit from April 8-10, 2025, this event is North America’s largest additive manufacturing and industrial 3D printing event.
Biographies
Alex Potts, Sales Manager – Hybrid Division, Phillips Corporation
Alex Potts is the Sales Manager for the Hybrid Division at Phillips Corporation. He has a background in materials science and engineering and is dedicated to advancing additive and hybrid manufacturing initiatives around the world.
Tommy Lynch, Senior Applications Engineer - Additive Manufacturing, Phillips Corporation
Tommy Lynch joined Phillips Corporation in July 2023. He brings over 20 years of industry experience operating industrial AM equipment and consulting clients on optimizing designs for both metal and polymer printing. Over the years, he has worked with thousands of customers to get their printing projects right on the first try. Tommy's success stems from his positive attitude, enthusiasm for new technologies and strong customer relationships.