Scaling hybrid manufacturing with an end-to-end part manufacturing solution

Introducing hybrid manufacturing trends and Big Metal Additive

Unlocking new levels of efficiency with additive manufacturing

Additive manufacturing has opened a world of possibilities engineers could only dream of previously. This workflow is known as hybrid, which is a combination of additive and subtractive manufacturing. This does not necessarily mean that these operations have to be done within the same work envelope. In other words, the additive operations can be done on one machine tool and the subtractive operations can be done on another, which is still considered hybrid. It certainly is advantageous to do all in a single machine tool when possible, which will cut down costs significantly, especially in terms of time.

Big Metal Additive – a hybrid manufacturing powerhouse

My recent visit to Big Metal Additive in Colorado had demonstrations of how true this is. BMA is a job shop that specializes in hybrid machining. They own multiple hybrid machine tools and articulated robots that can both machine and 3D print metal. When possible, the engineers there do as much of the work as they can in a single setup, which is due to the machine tools being muti-axis, meaning 5-axis for the CNC mills and 6-axis for the robots driven by SINUMERIK controls. 

Overcoming hybrid workflow challenges with integrated NX for Manufacturing

The size of the workpiece or the operations desired do not allow the work to be completely done on a single machine or even within the same shop. BMA occasionally outsources the parts they printed to shops with different capabilities such as turning. Although proven to be a viable option, this does come with its unique challenges. The machine shops receiving the outsourced work need to qualify the part before machining can take place, which is not so easy to do when the existing surfaces have all been 3D printed with a welder. Additional communications are needed between the two companies to ensure the part is correctly balanced within the existing stock so that designed features are not unintentionally removed the printed stock. 

The same challenge certainly exists for different machines within the same shop. The communications would be more immediate, but the balancing work can be tedious and time-consuming. Therefore it’s advantageous for users should keep the end-to-end operations all within the software, such as NX for Manufacturing. If all operations are kept within a single platform such as NX, then all design and manufacturing data are kept up to date and synchronized constantly.

For example, if a feature of the part design is changed, then the manufacturing operations can be updated to suit with a single button click. This is even true if the additive and subtractive setups are separated in different part files. So, even if the additive and subtractive operationss were planned for different machine tools, NX can help create different manufacturing setup part files for each machine, which are always linked back to the original part design. 

Additionally, both the Manufacturing and Multi-axis Deposition apps within NX are rich with a multitude of operation types, including milling, turning, additive, and EDM operations have multiple cut or deposition strategies for any configuration of these machine types to choose from. The additive operations are certainly newer, and keep growing, but the existing subtractive operations have been well proven and continue to improve over time, or new ones are added. When a hybrid workflow is desired, NX has all the tools necessary to build a part. 

Simplifying Additive Builds with Research-Driven Profiles

This is how BMA does their work. A constant synchronization of 3D printing and milling operations switching back and forth building parts from the ground up starting with nothing but some welding wire and a flat plate. What is created in the end is the perfect mixture of additive and subtractive for parts that are perfectly suited for their purpose.

This feature-by-feature build strategy is what separates the easy button from the serious additive applications. By using predefined profiles that work with little to no changes in the parameters for common materials, an inexperienced user can create a successful build very quickly with minimal training. 

Using a welder and a CNC machine to print metals is a different nuance. Eventually, additive specialists such as the engineers at BMA and additive machine tool OEM companies can capture additive build knowledge in a digital format. These specialists do a heavy amount of research to create standardized processes that will work for specific geometric shapes and materials. Putting this research directly into NX will make the next use case to be easier and quicker to replicate. 

The latest release of NX has new additive functionality known as the Printer Library, which allows expert to create a build profile based on their research for specified machine tools and materials. The true end user will then simply target an additive feature, select the build profile as advised by the research teams, and immediately generate some tool path. Since multiple profiles can be created for all types of operations and geometric shapes, one can imagine the tool path for an entire additive build being generated automatically. Now, engineers can dedicate more time researching new processes and less time to reprogramming the known ones. 

When you combine the new Printer Library capability with the existing automation capabilities of the subtractive operations in NX, such as custom manufacturing templates and feature-based machining, a full pathway to automating the hybrid machining workflow becomes possible.

Looking ahead: hybrid manufacturing in action

Big Metal Additive is more than just a shop — it’s a proving ground for the future of manufacturing. Their ability to seamlessly integrate additive and subtractive processes, backed by intelligent software like NX for Manufacturing, shows what’s possible when innovation meets execution.

As hybrid workflows become more accessible and automated, manufacturers like BMA are laying the groundwork for smarter, more agile production environments. Their hands-on experience, combined with research-driven process development, sets a new standard for how complex parts can be built — faster, better, and with fewer barriers.