There are lot of HYBRID AM TECHNIQUES and among them I would like to

explain 4 techniques. FIRST ONE IS,

1]DED(Direct energy deposition): In DED, we witness a fascinating process
where material is precisely deposited onto a substrate, layer by layer, using a
focused energy source such as a laser or an electron beam and here’s how it
works:
Firstly, we feed the material, typically in the form of wire or powder, into the
deposition zone. Then, with the help of our energy source, the material is melted
and fused onto the substrate in a controlled manner, following the exact path
outlined by a digital model of the desired part.
As each layer is deposited, it solidifies, building upon the previous layers to
form a solid, three-dimensional object. This layer-by-layer approach allows us
to create complex geometries with remarkable precision. It is used not only for
manufacturing but also for repairing and modifying.
And AMBIT™ is a first hybrid deposition and milling system introduced in
2013 and developed by US-based company which combined both additive man-
ufacturing and CNC milling capabilities in one machine.
*NOTE:- materials used:metals, polymers, and ceramics example: Siemens En-
ergy, a global leader in power generation technology, utilized DED additive
manufacturing to repair critical components for gas turbines.* deposition rate:
1 to 10 kilograms per hour.
SECOND ONE IS, 2]LENS(Laser engineered net shaping): here’s how it works:
1. **Powder Delivery:** We start by continuously feeding metallic powder into
the deposition area. These powders are carefully selected for their specific prop-
erties, ensuring we get the desired characteristics in our final product.
2. **Laser Melting:** A powerful laser beam is precisely directed onto the sur-
face of the substrate or previously deposited layer of powder. This intense heat
melts the powder particles, creating a molten pool of material at the targeted
location.
3. **Material Deposition:** Simultaneously, our motion control system kicks
into action, precisely positioning the laser beam and substrate to follow a pre-
defined path based on our digital model. As the laser moves along this path, it
selectively melts and fuses the powder particles, layer by layer, building up the
shape we want.
4. **Layer-by-Layer Buildup:** With each layer deposited and solidified, we
adjust the build platform or deposition head to accommodate the next layer of
powder. This process repeats iteratively, with the laser melting and fusing the
material to add more layers until our final object is complete.
5. **Cooling and Solidification:** As each layer is deposited, it rapidly cools
and solidifies, bonding with the previous layers to form a solid, fully dense part.

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We can control the cooling rates to optimize material properties and minimize
residual stresses, ensuring the quality of our fabricated object.
6. **Post-Processing:** Depending on our specific needs, our fabricated part
may undergo post-processing steps such as heat treatment, surface finishing,
machining, or inspection to achieve the desired quality, accuracy, and mechanical
properties.
*NOTE:- difference in 1] and 2] is:
1. Powder/Wire Delivery: - In LENS, metallic powder is continuously fed into
the deposition area through a nozzle or powder delivery system. - In DED,
material in the form of wire or powder is typically fed into the deposition zone.
2. Energy Source: - In LENS, a high-powered laser beam is precisely directed
onto the surface of the substrate or previously deposited layer of powder. - In
DED, a focused energy beam, such as a laser or an electron beam, is used to
melt the material as it is deposited onto the substrate. 3. Application: LENS
is primarily used for dense net like objects.
materials used:Stainless Steel Alloys Titanium Alloys Nickel-Based Alloys
(e.g., Inconel, Hastelloy) Aluminum Alloys Tool Steels (e.g., H13, D2) Cobalt-
Chromium Alloys (e.g., CoCrMo) Copper Alloys (e.g., bronze, brass) Precious
Metals (e.g., gold, silver, platinum) example:Optomec company is US-based
company which offers hybrid AM machines based on LENS technology.
depositon rate:5 to 500 grams per hour.*
AND THIRD ONE IS, 3] Selective Laser Sintering(SLS):here’s how it works:
1. **Powder Bed:** We start with a thin layer of powdered material spread
evenly across the build platform. This material can be a thermoplastic polymer
or a metal powder, depending on the application.
2. **Laser Sintering:** A high-powered laser beam is precisely directed onto the
surface of the powdered material. It selectively sinteres the particles together
at specific points based on a digital model of the object we want to create. This
process heats the powder to just below its melting point, causing it to fuse into
a solid layer.
3. **Layer-by-Layer Buildup:** After each layer is sintered, we lower the build
platform by a small increment and spread a new layer of powdered material
over the previous one. The laser then selectively sinters the next layer onto the
previous one. We repeat this process layer by layer until the entire object is
formed.
4. **Cooling and Solidification:** As each layer is sintered, it rapidly cools and
solidifies, forming a solid, fully dense part. We can control the cooling rates
to optimize material properties and minimize any stresses within the fabricated
object.

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5. **Post-Processing:** Once fabrication is complete, the 3D printed part may
undergo post-processing steps such as heat treatment, surface finishing, or sup-
port removal to achieve the desired final properties and appearance.
It’s widely used across industries like aerospace, automotive, medical, and con-
sumer goods for rapid prototyping, tooling, and creating functional end-use
parts.
*NOTE:-difference in 2] and 3] is:
1.Powder Bed Preparation: In LENS, metallic powder is continuously fed into
the deposition area through a nozzle or powder delivery system. In SLS, a thin
layer of powdered material is spread evenly across the build platform using a
roller or similar mechanism.
2.Laser Interaction: In LENS, the high-powered laser beam is precisely directed
onto the surface of the substrate or previously deposited layer of powder. The
laser rapidly melts the powder particles at the targeted location. In SLS, the
laser selectively sinters the powdered material together at specific points, heating
it to just below its melting point. This causes the particles to fuse into a solid
layer.
3.Material Deposition: In LENS, material is deposited layer by layer onto the
substrate or previously deposited layers, and the laser selectively melts and fuses
the powder material to form the desired shape. In SLS, material is built up layer
by layer as the laser sinters each layer of powdered material onto the previous
one, without the need for additional material deposition.
materials used: Thermoplastic Polymers:
Nylon (Polyamide) Polycarbonate (PC) Polyethylene (PE) Polypropylene (PP)
Polyetheretherketone (PEEK) Acrylonitrile Butadiene Styrene (ABS) Metals:
Aluminum Alloys Stainless Steel Alloys Tool Steels Titanium Alloys Cobalt-
Chromium Alloys Precious Metals (e.g., gold, silver) Ceramics:
Zirconia (ZrO2) Alumina (Al2O3) Silicon Carbide (SiC) Silicon Nitride (Si3N4)
Hydroxyapatite (HA)
example: Airbus uses SLS for rapid prototyping of components and parts used
in the design and development of new aircraft. SLS allows Airbus engineers to
quickly iterate and test different design concepts before committing to expensive
traditional manufacturing processes.
deposition rate: 5 to 50 cubic centimeters per hour