Case Study: How Hybrid Manufacturing Cut Lead Time by 40% in Aerospace Prototyping
An aerospace supplier reduced part production time by 40% using a hybrid manufacturing workflow combining metal 3D printing and CNC machining.
The integrated process minimized setups, improved accuracy, and accelerated iteration cycles on flight-critical components.
The Challenge
The company needed to prototype a titanium component with complex internal channels and multi-surface contours.
Traditional CNC machining required 5-axis setups, multiple fixtures, and extended toolpath programming—resulting in a 21-day lead time.
Key challenges:
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Complex undercuts and internal cavities
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Tight tolerances on mating surfaces
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Long setup and cycle time using only CNC methods
The Solution: Hybrid Manufacturing Workflow
Engineers used metal additive manufacturing to build the core geometry, then applied CNC finishing for precision features.
Process breakdown:
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Metal 3D Printing: Produced the rough part including lattice structures
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Stress Relief: Thermal post-processing for dimensional stability
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CNC Machining: Finished sealing faces, threads, and alignment features
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Inspection: CMM verified ±0.005 mm tolerances on all critical areas
Turning operations were used to finish cylindrical features—see relevant CNC turning services used in this workflow.
The Results
| Metric | Before (CNC-only) | After (Hybrid) | Improvement |
|---|---|---|---|
| Total Lead Time | 21 days | 12 days | -43% |
| Setup and fixturing time | 8 hours | 3 hours | -63% |
| Part accuracy (critical zones) | ±0.01 mm | ±0.005 mm | Improved |
| Material waste | High (60% loss) | Low (<20%) | More efficient |
Conclusion:
Hybrid workflows reduced total cycle time and waste while achieving higher accuracy and faster iteration—ideal for aerospace prototyping.