Hybrid Additive-Subtractive Manufacturing of Multi-Material Functionally Graded Components: Integration of Laser Powder Bed Fusion with High-Speed CNC Finishing for Aerospace Applications

Year : 2026 | Volume : 14 | Special Issue 02 | Page : 398 418
    By

    M. Nithin Srinivas,

  • S. N. Padhi,

  1. M.Tech Student, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur, Andhra Pradesh, India
  2. Professor, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur, Andhra Pradesh, India

Abstract

The synergy involved in the merging of additive and subtractive manufacturing technologies is the game changer to generate multi-material functionally graded components to be used in the aerospace industries. The paper is an in-depth review of a proposed hybrid additive-subtractive manufacturing, which synergistically merges laser powder bed fusion (LPBF) fashioning with rapid computer numerical control finishing production processes. The multi-material deposition, thermal issues, and optimization of post-processing are the challenges faced by the technique that have been considered analytically towards realizing ever-heaviest component performance and manufacturing efficiency. Advanced technology developed under a novel multi-material powder delivery system allows controlling the formation of composition gradients with high precision. It can also make predictions of reducing the residual stress in the LPBF process by an advanced thermal effects model. Real-time monitoring process, adaptive control systems, and intelligent tool path planning are also integrated in order to provide maximum optimization to the transition process between additive and subtractive operations. Experimental validation on Ti-6Al-4V/Inconel 625 functionally graded aerospace components demonstrates exceptional results: 68% reduction in surface roughness (from 25.6 μm to 8.2 μm Ra), 45% improvement in dimensional accuracy (±0.05 mm tolerance achievement), 52% increase in fatigue life, and 35% reduction in total processing time compared to conventional manufacturing approaches. The hybrid system is 97% efficient on material utilization and allows geometrical complex parts to be manufactured that would not have been produced with previous production methods. In three aerospace industry manufacturing facilities, a return of investment of 312%, along with break-even from between 18 months and five years, was spotted.

Keywords: Hybrid manufacturing, Additive -subtractive integration, laser powder bed fusion, multi-material processing, functionally graded materials, aerospace manufacturing.

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
M. Nithin Srinivas, S. N. Padhi. Hybrid Additive-Subtractive Manufacturing of Multi-Material Functionally Graded Components: Integration of Laser Powder Bed Fusion with High-Speed CNC Finishing for Aerospace Applications. Journal of Polymer & Composites. 2026; 14(02):398-418.
How to cite this URL:
M. Nithin Srinivas, S. N. Padhi. Hybrid Additive-Subtractive Manufacturing of Multi-Material Functionally Graded Components: Integration of Laser Powder Bed Fusion with High-Speed CNC Finishing for Aerospace Applications. Journal of Polymer & Composites. 2026; 14(02):398-418. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239794


References

  1. Gibson, I., Rosen, D., Stucker, B., & Khorasani, M. (2021). Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing. Springer Nature. DOI: 10.1007/978-3-030-56127-7
  2. Zhu, Z., Dhokia, V. G., Nassehi, A., & Newman, S. T. (2013). A review of hybrid manufacturing processes–state of the art and future perspectives. International Journal of Computer Integrated Manufacturing, 26(7), 596-615. DOI: 10.1080/0951192X.2012.749530
  3. Lauwers, B., Klocke, F., Klink, A., Tekkaya, A. E., Neugebauer, R., & Mcintosh, D. (2014). Hybrid processes in manufacturing. CIRP Annals, 63(2), 561-583. DOI: 10.1016/j.cirp.2014.05.004
  4. Naebe, M., & Shirvanimoghaddam, K. (2016). Functionally graded materials: A review of fabrication and properties. Applied Materials Today, 5, 223-245. DOI: 10.1016/j.apmt.2016.10.001
  5. Reichardt, A., Dillon, R. P., Borgonia, J. P., Shapiro, A. A., McEnerney, B. W., Momose, T., & Hosemann, P. (2021). Development and characterization of Ti-6Al-4V to 304L stainless steel gradient components fabricated with laser deposition additive manufacturing. Materials & Design, 104, 404-413. DOI: 10.1016/j.matdes.2016.05.016
  6. Flynn, J. M., Shokrani, A., Newman, S. T., & Dhokia, V. (2016). Hybrid additive and subtractive machine tools–research and industrial developments. International Journal of Machine Tools and Manufacture, 101, 79-101. DOI: 10.1016/j.ijmachtools.2015.11.007
  7. Klocke, F., Arntz, K., Teli, M., Winands, K., Wegener, M., & Oliari, S. (2017). State-of-the-art laser additive manufacturing for hot-work tool steels. Procedia CIRP, 63, 58-63. DOI: 10.1016/j.procir.2017.03.073
  8. Carroll, B. E., Palmer, T. A., & Beese, A. M. (2015). Anisotropic tensile behavior of Ti–6Al–4V components fabricated with directed energy deposition additive manufacturing. Acta Materialia, 87, 309-320. DOI: 10.1016/j.actamat.2014.12.054
  9. Merklein, M., Junker, D., Schaub, A., & Neubauer, F. (2016). Hybrid additive manufacturing technologies–an analysis regarding potentials and applications. Physics Procedia, 83, 549-559. DOI: 10.1016/j.phpro.2016.08.057
  10. Stavropoulos, P., Foteinopoulos, P., Papacharalampopoulos, A., & Bikas, H. (2018). Addressing the challenges for the industrial application of additive manufacturing: Towards a hybrid solution. International Journal of Lightweight Materials and Manufacture, 1(3), 157-168. DOI: 10.1016/j.ijlmm.2018.07.002
  11. Du, W., Bai, Q., & Zhang, B. (2016). A novel method for additive/subtractive hybrid manufacturing of metallic parts. Procedia Manufacturing, 5, 1018-1030. DOI: 10.1016/j.promfg.2016.08.067
  12. Newman, S. T., Zhu, Z., Dhokia, V., & Shokrani, A. (2015). Process planning for additive and subtractive manufacturing technologies. CIRP Annals, 64(1), 467-470. DOI: 10.1016/j.cirp.2015.04.109
  13. Kieback, B., Neubrand, A., & Riedel, H. (2003). Processing techniques for functionally graded materials. Materials Science and Engineering: A, 362(1-2), 81-106. DOI: 10.1016/S0921-5093(03)00578-1
  14. Goldak, J., & Akhlaghi, M. (2005). Computational Welding Mechanics. Springer Science & Business Media. DOI: 10.1007/b101137
  15. Sing, S. L., An, J., Yeong, W. Y., & Wiria, F. E. (2016). Laser and electron-beam powder-bed additive manufacturing of metallic implants: A review on processes, materials and designs. Journal of Orthopaedic Research, 34(3), 369-385. DOI: 10.1002/jor.23075
  16. Cortina, M., Arrizubieta, J. I., Ruiz, J. E., Ukar, E., & Lamikiz, A. (2018). Latest developments in industrial hybrid machine tools that combine additive and subtractive operations. Materials, 11(12), 2583. DOI: 10.3390/ma11122583
  17. Tan, C., Zhou, K., Ma, W., Zhang, P., Liu, M., & Kuang, T. (2017). Microstructural evolution, nanoprecipitation behavior and mechanical properties of selective laser melted high-performance grade 300 maraging steel. Materials & Design, 134, 23-34. DOI: 10.1016/j.matdes.2017.08.026
  18. Wang, Z., Guan, K., Gao, M., Li, X., Chen, X., & Zeng, X. (2012). The microstructure and mechanical properties of deposited-IN718 by selective laser melting. Journal of Alloys and Compounds, 513, 518-523. DOI: 10.1016/j.jallcom.2011.10.107
  19. Boggarapu, V., Gujjala, R., Ojha, S., Acharya, S., Chowdary, S., & Kumar Gara, D. (2021). State of the art in functionally graded materials. Composite Structures, 262, 113596. DOI: 10.1016/j.compstruct.2021.113596
  20. Yan, W., Ge, W., Smith, J., Lin, S., Kafka, O. L., Lin, F., & Liu, W. K. (2017). Multi-scale modeling of electron beam melting of functionally graded materials. Acta Materialia, 115, 403-412. DOI: 10.1016/j.actamat.2016.06.022
  21. Mercelis, P., & Kruth, J. P. (2006). Residual stresses in selective laser sintering and selective laser melting. Rapid Prototyping Journal, 12(5), 254-265. DOI: 10.1108/13552540610707013
  22. Tian, Y., Tomus, D., Rometsch, P., & Wu, X. (2017). Influences of processing parameters on surface roughness of Hastelloy X produced by selective laser melting. Additive Manufacturing, 13, 103-112. DOI: 10.1016/j.addma.2016.10.010
  23. Altintas, Y. (2012). Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design. Cambridge University Press. DOI: 10.1017/CBO9780511843723
  24. Tlusty, J., & MacNeil, P. (1975). Dynamics of cutting forces in end milling. CIRP Annals, 24(1), 21-25.
  25. Hall, D. L., & Llinas, J. (1997). An introduction to multisensor data fusion. Proceedings of the IEEE, 85(1), 6-23. DOI: 10.1109/5.554205
  26. ISO 1101:2017. Geometrical product specifications (GPS) — Geometrical tolerancing — Tolerances of form, orientation, location and run-out. International Organization for Standardization.
  27. ISO 4287:1997. Geometrical Product Specifications (GPS) — Surface texture: Profile method — Terms, definitions and surface texture parameters. International Organization for Standardization.
  28. Hashin, Z., & Shtrikman, S. (1963). A variational approach to the theory of the elastic behaviour of multiphase materials. Journal of the Mechanics and Physics of Solids, 11(2), 127-140. DOI: 10.1016/0022-5096(63)90060-7
  29. Montgomery, D. C. (2019). Introduction to Statistical Quality Control. John Wiley & Sons.
  30. Deb, K., Pratap, A., Agarwal, S., & Meyarivan, T. A. M. T. (2002). A fast and elitist multiobjective genetic algorithm: NSGA-II. IEEE Transactions on Evolutionary Computation, 6(2), 182-197. DOI: 10.1109/4235.996017
  31. LeCun, Y., Bengio, Y., & Hinton, G. (2015). Deep learning. Nature, 521(7553), 436-444. DOI: 10.1038/nature14539
  32. Zienkiewicz, O. C., Taylor, R. L., & Zhu, J. Z. (2013). The Finite Element Method: Its Basis and Fundamentals. Butterworth-Heinemann. DOI: 10.1016/B978-1-85617-633-0.00001-0
  33. Randall, R. B. (2011). Vibration-based Condition Monitoring: Industrial, Aerospace and Automotive Applications. John Wiley & Sons. DOI: 10.1002/9780470977668
  34. Porter, D. A., Easterling, K. E., & Sherif, M. (2009). Phase Transformations in Metals and Alloys. CRC Press. DOI: 10.1201/9781439883570
  35. Kingery, W. D., Bowen, H. K., & Uhlmann, D. R. (1976). Introduction to Ceramics. John Wiley & Sons.
  36. Shewmon, P. (2016). Diffusion in Solids. DOI: 10.1007/978-3-319-48206-4
  37. Steen, W. M., & Mazumder, J. (2010). Laser Material Processing. Springer Science & Business Media. DOI: 10.1007/978-1-84996-062-5
  38. Lee, E. A. (2008). Cyber physical systems: Design challenges. 2008 11th IEEE International Symposium on Object and Component-Oriented Real-Time Distributed Computing (ISORC), 363-369. DOI: 10.1109/ISORC.2008.25
  39. Nakamoto, S. (2008). Bitcoin: A peer-to-peer electronic cash system. Decentralized Business Review, 21260.
  40. Uma Mageswari, S., Subramanian, N., Srinivasan, H., & Sridhar, R. (2023). Assessment of groundwater quality and human health risk from nitrate and fluoride contamination in Sivaganga district, Tamil Nadu, India. Environmental Geochemistry and Health, 45(2), 511-534. DOI: 10.1007/s10653-022-01234-5
  41. Saibabaa, M. A., Sankar, G. R., Krishnaiah, G., & Rao, M. N. (2022). Free vibration response of smart functionally graded magneto-electro-elastic nanobeams in hygro-thermal environment. Structures, 44, 1047-1064. DOI: 10.1016/j.istruc.2022.08.044
  42. Padhi, S., Sahu, S. K., Kumari, P., & Jena, S. K. (2019). Parametric instability analysis of functionally graded CNT-reinforced composite plates under non-uniform in-plane periodic loading. Composite Structures, 212, 162-175. DOI: 10.1016/j.compstruct.2019.01.024
  43. Roland, T., Reiss, J., Zakharova, A., & Schöll, E. (2022). Solitary states for coupled oscillators with inertia. Chaos, 32(10), 103122. DOI: 10.1063/5.0101220
  44. Vinayaka, K., Krishnamurthy, N., Praveena, G. S., & Kumar, G. V. P. (2023). Tribological behavior of Al-CNT nanocomposite fabricated by powder metallurgy technique. Materials Today: Proceedings, 72, 2291-2297. DOI: 10.1016/j.matpr.2022.09.294.
Special Issue Subscription Review Article
Volume 14
Special Issue 02
Received 03/11/2025
Accepted 17/11/2025
Published 07/04/2026
Publication Time 155 Days
109

Login


My IP

PlumX Metrics