Hybrid Manufacturing:Combining Titanium 3D Printing with CNC Finish Machining
The rise of metal Additive Manufacturing(AM)has unlocked previously impossible geometries,such as topology-optimized lattices and integrated cooling channels.However,”as-printed”surfaces and dimensional accuracy are often insufficient for high-performance sports components that require precise bearings,seals,or threads.The solution lies in hybrid manufacturing,a core DHT capability that strategically combines the form-freedom of Titanium 3D Printing with the precision of CNC machining.
Defining the Hybrid Workflow
This is not merely post-processing; it’s an integrated production strategy.
Design for Hybrid
The component is designed as a single part, but with clear zones. Complex, lightweight internal structures are designed for AM, while critical functional interfaces (e.g., bearing bores, mounting flanges) are designed with excess stock for CNC machining.
Additive Step
The part is 3D printed in Ti-6Al-4V using LPBF (Laser Powder Bed Fusion) technology. The print is oriented to optimize mechanical properties and minimize support structures on critical surfaces.
Stress Relief & Preparation
The printed “near-net-shape” undergoes stress relief heat treatment. It is then mounted in a precision fixture using datum features printed into non-critical areas.
Subtractive Step
CNC machining then takes over. The fixture ensures the part is located in a known coordinate system, allowing 5-axis CNC to accurately machine the bearing seats, threads, and mating surfaces to tolerances of ±0.02mm and surface finishes of Ra <0.8μm.
Applications in High-Performance Sports
This hybrid approach is transformative for:
Custom Motorcycle/Bicycle Brake Caliper Mounts
A topology-optimized, lightweight bracket printed in titanium, with perfectly machined mounting holes and disc alignment faces.
High-End Drone Motor Mounts
An integrated structure with internal vibration-damping lattices and CNC-machined flat, parallel surfaces for motor and arm attachment.
Wearable Sensor Housings
An ergonomic, complex-form housing printed as one piece, with precision-machined ports for waterproof connectors.
The DHT Advantage: Integrated Process Control
The key to hybrid success is controlling both processes under one roof. DHT manages the entire chain—from powder handling and print parameter optimization to precision fixturing and final machining. This eliminates coordination loss between separate vendors and guarantees that the print orientation supports the final machining strategy, resulting in a part that leverages the full potential of both advanced manufacturing technologies.
For engineers, this means no longer having to choose between optimal design and precision execution; with DHT’s hybrid manufacturing, you can have both.
