Hybrid manufacturing combines DMLS metal printing with secondary machining on the features that drive fit, sealing, alignment, and assembly. After printing, stress relief and support removal, we CNC machine critical bores, datums, sealing faces, threads and interfaces to improve tolerance control. The result is additive geometry where it adds value and machined precision where the part needs tighter control.
Advanced manufacturing capabilities enable complex geometries, functional prototypes, and end-use production parts that would be impossible or cost-prohibitive with traditional manufacturing methods. From functional prototypes to end-use production parts, this technology delivers exceptional performance across demanding industries.
Hybrid Technology · Production-Ready
Advanced Applications
The Hybrid manufacturing process delivers precision parts through controlled layer-by-layer construction, ensuring consistent quality and mechanical properties.
The Hybrid manufacturing process delivers precision parts through controlled layer-by-layer construction, ensuring consistent quality and mechanical properties.
Complex geometries: Intricate internal channels, overhangs, and assemblies impossible with traditional manufacturing.
Functional prototypes: Test mechanical properties and fit before investing in production tooling.
Custom tooling: Jigs, fixtures, and manufacturing aids tailored to specific production requirements.
End-use parts: Production components for aerospace, medical, automotive, and industrial applications.
Every hybrid job moves from DMLS build planning into post-print processing, machining of critical features, and final inspection. The goal is not to machine the whole part from billet, but to selectively improve the surfaces and dimensions that determine whether the printed component works in the final assembly.
Step 1 of 4
Engineering reviews the DMLS geometry first, then defines which features stay as-printed and which require machining stock, datums, and secondary finishing.
Step 2 of 4
Metal parts are printed, stress relieved, and cleaned so the component is stable before any machining references are established.
Step 3 of 4
Precision milling, drilling, threading, or turning is applied only to the critical DMLS features that need tighter fit, flatter surfaces, or better positional control.
Step 4 of 4
Finished hybrid parts are deburred, surface treated as required, and inspected on the machined features that control fit, assembly, and release readiness.
Large machining envelopes accommodate oversized parts or multi-setup fixtures with precision up to Dependent on DMLS part.
Hybrid DMLS finishing for tight-tolerance bores, datums, threads, and sealing surfaces to Geometry Dependant.
Cycle time optimized to geometry, toolpaths, and material selection using Cycle times optimized per feature set and fixture strategy.
These materials reflect the DMLS metal alloys most often routed into secondary machining for tighter interfaces, improved sealing surfaces, and assembly-critical geometry.
Aluminum 6061 is a versatile precipitation-hardened alloy that combines magnesium and silicon as primary alloying elements to achieve exceptional mechanical properties.
This heat-treatable alloy offers an outstanding balance of strength, ductility, and corrosion resistance, making it ideal for structural applications where high performance and reliability are essential.
High-Strength Structural Aluminum Alloy
Applications
Aerospace Structures/Automotive Components/Marine Hardware/Precision Fixtures
Stainless Steel 316L is the most popular 3D printed metal at Forge Labs for corrosion-resistant 3D printed parts.
It combines high strength, excellent ductility, and strong chloride resistance, making it a go-to material for marine hardware, chemical processing equipment, food production components, and precision industrial assemblies.
Marine-Grade Austenitic Stainless Steel
Compliance
ASTM F138 (UNS S31673) chemistry/REACH Regulation (EC) 1907/2006
Applications
Industrial Components/Chemical Processing/Food Processing/Marine Applications
Titanium Ti-6Al-4V (Grade 5) is the most widely used titanium alloy in aerospace and automotive applications.
This alpha-beta alloy offers an exceptional strength-to-weight ratio and excellent corrosion resistance.
Aerospace-Grade Lightweight Alloy
Compliance
ASTM B348 Grade 5/ASTM F2924/ASTM F3302
Applications
Aerospace Structures/Precision Components/Automotive Racing/Sports Equipment
Maraging Steel MS1 is a ultra-high strength steel with exceptional hardness and dimensional stability achieved through precipitation hardening.
With its 18% nickel content and low carbon composition, it delivers superior mechanical properties ideal for precision tooling applications.
Ultra-High Strength Steel for Precision Tooling
Applications
Injection Molding Tools/Mechanical Engineering/Precision Tooling/Aerospace Tooling
Stainless steel 304 is widely used for CNC machined parts that require excellent corrosion resistance, hygienic performance, and long service life.
It is ideal for consumer products, laboratory equipment, and marine environments.
Corrosion Resistant Austenitic Stainless Steel
Compliance
ASTM A240/A240M (UNS S30400)/ASTM A276 / A479 (UNS S30400)/NSF food equipment acceptance
Applications
Food and Beverage Equipment/Corrosion Resistant Housings/Medical Fixtures
Delrin combines excellent machinability with low friction, making it ideal for CNC machined components that require smooth motion, tight tolerances, and wear resistance without lubrication.
Dimensional stability and high fatigue resistance support precise motion hardware and durable wear surfaces.
Low Friction Engineering Plastic
Compliance
FDA 21 CFR 177.2480 (Food contact)/NSF/ANSI 51 and 61/ASTM D6100 S-POM0111 / ASTM D6778 POM0111
Applications
Motion Components/Fixtures and Jigs/Fluid Handling
High-Strength Structural Aluminum Alloy
Aluminum 6061 is a versatile precipitation-hardened alloy that combines magnesium and silicon as primary alloying elements to achieve exceptional mechanical properties. This heat-treatable alloy offers an outstanding balance of strength, ductility, and corrosion resistance, making it ideal for structural applications where high performance and reliability are essential.
Tensile Strength
331 MPa
Elastic Modulus
76 GPa
Temp Resistance
See datasheet
Applications
Aerospace Structures/Automotive Components/Marine Hardware/Precision Fixtures
Marine-Grade Austenitic Stainless Steel
Stainless Steel 316L is the most popular 3D printed metal at Forge Labs for corrosion-resistant 3D printed parts. It combines high strength, excellent ductility, and strong chloride resistance, making it a go-to material for marine hardware, chemical processing equipment, food production components, and precision industrial assemblies.
Tensile Strength
630 MPa
Elastic Modulus
185 GPa
Temp Resistance
See datasheet
Compliance
ASTM F138 (UNS S31673) chemistry/REACH Regulation (EC) 1907/2006
Applications
Industrial Components/Chemical Processing/Food Processing/Marine Applications
Aerospace-Grade Lightweight Alloy
Titanium Ti-6Al-4V (Grade 5) is the most widely used titanium alloy in aerospace and automotive applications. This alpha-beta alloy offers an exceptional strength-to-weight ratio and excellent corrosion resistance.
Tensile Strength
1080 MPa
Elastic Modulus
110 GPa
Temp Resistance
350 °C
Compliance
ASTM B348 Grade 5/ASTM F2924/ASTM F3302
Applications
Aerospace Structures/Precision Components/Automotive Racing/Sports Equipment
Ultra-High Strength Steel for Precision Tooling
Maraging Steel MS1 is a ultra-high strength steel with exceptional hardness and dimensional stability achieved through precipitation hardening. With its 18% nickel content and low carbon composition, it delivers superior mechanical properties ideal for precision tooling applications.
Tensile Strength
1200 / 1100 MPa
Elastic Modulus
150 / 140 GPa
Temp Resistance
400 °C
Applications
Injection Molding Tools/Mechanical Engineering/Precision Tooling/Aerospace Tooling
Corrosion Resistant Austenitic Stainless Steel
Stainless steel 304 is widely used for CNC machined parts that require excellent corrosion resistance, hygienic performance, and long service life. It is ideal for consumer products, laboratory equipment, and marine environments.
Tensile Strength
515 MPa
Flexural Modulus
193 GPa
Temp Resistance
870 °C
Compliance
ASTM A240/A240M (UNS S30400)/ASTM A276 / A479 (UNS S30400)/NSF food equipment acceptance
Applications
Food and Beverage Equipment/Corrosion Resistant Housings/Medical Fixtures
Low Friction Engineering Plastic
Delrin combines excellent machinability with low friction, making it ideal for CNC machined components that require smooth motion, tight tolerances, and wear resistance without lubrication. Dimensional stability and high fatigue resistance support precise motion hardware and durable wear surfaces.
Tensile Strength
76 MPa
Flexural Modulus
2900 MPa
Temp Resistance
169 °C
Compliance
FDA 21 CFR 177.2480 (Food contact)/NSF/ANSI 51 and 61/ASTM D6100 S-POM0111 / ASTM D6778 POM0111
Applications
Motion Components/Fixtures and Jigs/Fluid Handling
Hybrid metal parts can leave selected surfaces as-printed while machining and finishing the interfaces that control assembly, sealing, and appearance.
Parts deburred and cleaned straight from the machine with visible tool marks. Ideal for functional components and internal features where cosmetic appearance is not critical.
Finish attributes
Anodizing adds a controlled oxide layer to compatible aluminum components, improving corrosion resistance, surface durability, and cosmetic consistency on finished hybrid metal parts.
Finish attributes
Includes bead blasting, anodizing, electropolishing, painting, and part marking tailored to your specification.
Finish attributes
Machined DMLS parts succeed when machining allowances, workholding, finishing, and inspection are planned alongside the additive build.
Machining stock planning
Define which DMLS faces, bores, and threads need extra stock before the part is printed.
Custom fixturing and datum strategy
Reference irregular printed geometry reliably during secondary machining.
Critical feature finishing
Machine sealing surfaces, bolt patterns, threads, and interfaces that control fit and function.
Upload files, configure manufacturing specs, and track production in one workflow built for engineering teams.
75% complete
Step 01
Automated file checks before production
Drop your CAD files and receive immediate manufacturability feedback. Critical geometry and wall checks run as soon as files are uploaded.
CNC machining is used when tight tolerances, surface finish, and predictable material performance are non-negotiable. Teams use CNC for fixtures, brackets, enclosures, prototypes, and production components across metals and engineering plastics.
Machining is the default choice for production-ready parts when you need tight dimensional control, broad material selection, and established finishing options. It is often used for first articles, fixtures, and end-use components that must match spec without process variability.
Lightweight printed brackets where bolt patterns, bores, and mounting faces are machined after build.
Example parts
Aerospace / Defense
Printed metal housings with internal geometry preserved while ports, sealing surfaces, and threads are post-machined.
Example parts
Industrial Equipment / Robotics
Flight-weight components produced by DMLS and finished with CNC machining for qualification-critical interfaces.
Example parts
Aerospace / Space
Highlighted Case Study
Aerospace
Complex metal housing printed with internal features intact and machined afterward on connector and mounting interfaces.
Read case studyUpload your CAD files to review hybrid DMLS plus CNC post-processing for tolerance-critical metal parts. Production-ready manufacturing with fast turnaround times.
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STEP, STL, OBJ, 3MF and IGES supported
Common questions about hybrid manufacturing workflows for DMLS metal parts. Can't find what you're looking for? Reach out to our technical team.
