Hybrid Pilot Projects

Low-Risk Validation for Hybrid Manufacturing

Applications Open

Hybrid CNC Parts’ Hybrid Pilot Projects help engineering and manufacturing teams test fit, prove feasibility, and define a repeatable workflow for projects considering a wire-laser hybrid approach. Each pilot is structured to reduce uncertainty and produce clear technical outcomes.

HCP staff measure a hybrid manufactured part

What is a Hybrid Pilot Project?

A Hybrid Pilot Project is a scoped first engagement using wire-laser hybrid manufacturing, which combines wire-laser deposition and CNC machining into a single planned workflow. The goal is not just to “try additive,” but to determine whether hybrid manufacturing improves cost, lead time, manufacturability, or performance for a specific part or application.

Wire-laser hybrid manufacturing integrates directed energy deposition (DED) and CNC machining within a single setup. Wire feedstock is deposited through a controlled laser melt pool to create near-net geometry, then machined in place to final dimensions and tolerances.

Geometries and materials that are too complex, expensive, or difficult to work with conventionally are enabled using wire-laser hybrid methods, unlocking significant performance improvements.

This approach retains the control and inspection discipline of conventional machining while expanding material and design options beyond additive- or subtractive-only workflows.

Wire-laser hybrid manufacturing addresses conditions where conventional workflows tend to concentrate risk—such as demanding environments, tight schedules, low production volumes, or elevated qualification requirements.

Example applications include:

  • Low-volume or first-of-kind projects that would be too costly or time-consuming using conventional manufacturing methods.
  • Parts requiring targeted material performance, such as enhanced corrosion, heat, and wear resistance.
  • Schedule-critical components with tight timelines.
  • Parts with functional or internal geometries that would be impossible to produce with additive- or subtractive-only methods.
  • Components that are comprised of high-value alloys.
  • Specialty parts better suited to repair and refurbishment, rather than replacement.
  • Legacy components where suppliers or tooling is no longer available.

Best-Fit Project Types

If any of the following apply, your project is likely a good fit for a pilot:

  • Your part is complex, expensive, or slow to produce from solid stock.
  • Your program needs a practical path from concept to a repeatable manufacturing plan.
  • Your design includes complex features that would benefit from strategic material building before finishing.
  • Your parts have high material cost or scrap rates, where reducing waste matters.
  • Your components have localized performance needs, where placing performance material selectively would improve outcomes.
  • A supplier change, schedule pressure, or material constraint is making your current approach risky.
  • Your project is on a strict timeline, where cost-of-delay is a greater consideration than cost-per-unit.
  • Your program needs a feasibility proof point before committing to a different production approach.

What to Expect

Each Hybrid Pilot Project will look slightly different, depending on requirements. However, in general you can expect:

Fit & Feasibility Review
Review of geometry, requirements, material needs, and success criteria to confirm hybrid fit.

Process Planning
CAD design, if required. Build strategy of deposition and machining operations, with critical datums and features defined up front.

Pilot Build
First article and lot manufactured using the planned hybrid workflow, with CNC finishing to the required interfaces and tolerances.

Results & Recommendations
Full documentation, including testing and validation (as applicable) and what the next step should be for repeatability or scale.

Apply Today

Submit a pilot inquiry to start a feasibility review. Pilot slots are limited and applications will be reviewed on a first come, first served basis.

Your inquiry should include :

  • A CAD/drawing (if available), or clear description of the part and its function.
  • Material requirements or constraints, if known.
  • The features that matter most, including tolerances, interfaces, and inspection expectations.
  • Your pilot success criteria (lead time, cost, manufacturability, performance, or risk reduction).

How to Apply

Email pilotproject@hybridcncparts with the above information. Include “Hybrid Pilot Project Application” in the subject.

Question? Contact us at (508)-461-9412 or support@hybridcncparts.com.