What it takes to convert your machine shop into a hybrid operation

How did this happen? As AM technology has advanced, subtractive manufacturers have begun incorporating techniques into their own operations, with a growing number offering additive capabilities alongside their traditional machines. Here’s what manufacturers can gain from incorporating AM at their facility, and what it takes to become a hybrid operation.

The benefits of a hybrid manufacturing operation
Many players in the manufacturing sector, from job shops to production facilities, are becoming hybrid operations. Advancements in 3D printing along with new metal AM technologies allow traditional machine shops to pivot to hybrid with additive and subtractive processes operating side by side. In addition, a new generation of hybrid machines are even offering printing and CNC capabilities in one piece of equipment, completely fusing AM and subtractive techniques into one seamless workflow.

Combining subtractive and AM production methods in your company offers benefits both on the shop floor and in the boardroom. At the business level, hybrid operations help:

• Expand service offerings. Combined AM and subtractive capabilities enable you to manufacture new types of products and meet more specifications. 
• Target new customers. Expanded capabilities allow you to appeal to a wider array of customers, including those in niche industries or with a strong need for innovation. 
• Gain a competitive advantage. Diversifying your customer base and operations can help you expand market share and protect your business from economic downturns, allowing you to stay competitive with other manufacturers in your area.

During production, hybrid operations will:

• Increase productivity. Combining AM and subtractive capabilities in the same space (or even the same machine) streamlines workflows for higher output in less time.
• Reduce waste. Using AM methods can reduce the material consumption associated with subtractive manufacturing as parts are created near net shape. Subtractive cutting techniques can also improve finish quality for AM parts and are often needed for sealing surfaces and precise hole and surface geometries, further adding to cost-savings. 

How to convert to a hybrid machine shop
Transforming your operation into a hybrid machine shop requires significant equipment investments and process changes. Here are the investments you’ll want to consider to get started:

• AM machinery. Hybrid production can’t occur without investing in AM machines. Often companies begin by purchasing only one machine at a time to gradually refine your offerings and to avoid over-scaling. Aggressively adopting AM more than necessary could result in implementation challenges, especially as 3D printing and hybrid additive and subtractive machinery continues evolving at a rapid pace. Remember that capital investments need long-haul consideration. 
• AM software. In addition to the software needed to operate 3D printers and other AM equipment, you’ll need computer aided design (CAD) programs to develop the 3D models being produced. Data capacity and computing is an important consideration when looking into AM processes. Research the market carefully, or consult your equipment manufacturers for more insight into the software that’s compatible (and capable) for your operation.
• New material-compatible cutting tools and coolant. The next-generation material powders and wire often used in 3D printing have characteristics that make them different to machine than traditional materials. If adding AM capabilities to your traditional operation, consult with tooling manufacturers and distributors to ensure your cutting tools are compatible with the next-generation materials that come out of AM machinery. Even cutting fluid may need to be upgraded to higher performance and more versatile products that provide the necessary cooling and lubricity to these new AM materials. 

After you’ve made your initial capital investments in hybrid technology, you'll also need to significantly change the way you run your business. Next, focus on:

• Training. Designing and engineering parts for additive manufacturing requires advanced skill sets. For successful conversion to a hybrid operation, you’ll need employees who can check the viability of CAD files, make changes, and operate AM machines efficiently. Enroll workers in courses, develop a training program internally, or leverage learning materials from machine manufacturers to ensure employees can work effectively. Consider joining industry organizations such as America Makes. 
• KPI tracking. Additive manufacturing processes automate many aspects of production, enabling computers to track key performance indicators (KPIs) like output, scrap rate, and cycle times. Be diligent about using the data tracking capabilities available through your machinery or AM software, and expand tracking to every aspect of your operation. 
• Process refinement. When you measure performance, it lays the foundation for overall process improvement — because anything you can measure is something you can make better. Monitor KPIs and look for red flags like a high scrap rate or excessive coolant or cutting tool consumption so you can correct issues and improve cost savings on an ongoing basis. 

Additive manufacturing techniques are rapidly advancing and have much to offer traditional manufacturers and their customers. Adding AM to your capabilities and workflows will help your company reduce waste and achieve greater efficiency — while helping the industry usher in a new paradigm.