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Large scale open hybrid AM system (additive + subtractive)

Oct 2016 – Sep 2019


The objective of this project was the development of an advanced hybrid additive and subtractive system based on laser cladding, using both wire and powder raw material, together with 5 axes machining. The new system was successfully incorporated in a large scale gantry platform and also a medium sized milling machine enabling the automated repair of high value engineering components.

Key activities

  • Development of new interchangeable process tools: Laser deposition (smart powder feed and novel wire feed head); Stress relieving; Part inspection.
  • Development of a suite of easy to use CAM software for prescriptive and adaptive repair.
  • Development and validation of hybrid DED process simulation tools.
  • Integrate the technology in two new platforms: 5-axis milling machine (GF); gantry platform (Gudel).
  • Demonstrate the benefits of the approach for the repair of industrial demonstrators: Mineral processing equipment (Weir); Steam turbine blades (Siemens); Automotive press tools (CRF).


The new system provides a flexible, automated, cost effective and repeatable solution for the repair of complex high value engineering components which can be integrated in a wide range of machine platforms and readily configures for the particular application.

MTC role in project

  • Project coordinator.
  • Testing and development of operating parameters for the new processing heads.
  • Development of NDT system to enable in-process inspection of parts.
  • Supporting the repair of the demonstration parts.

Other details

  • Project partners: Manufacturing Technology Centre (MTC), Gudel, GF Machining Solutions, Hybrid Manufacturing Technologies Ltd (HMT), The Welding Institute (TWI), Fraunhofer IPT, BCT, Picasoft, ESI, Centro Ricerche Fiat (CRF), Weir Group, Siemens, European Welding Federation (EWF).
  • Funding body: EU - H2020 / FoF1 – 2016 / Project: 723917
  • Project budget: €6.6m
  • Grant to MTC: €962k
  • Link to Project website:


This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement H2020–FoF-2016- 723917-OPENHYBRID.