Blog

How Hybrid CNC Machining Is Changing Metal Manufacturing

Producing a complex metal component can require several machines, multiple setups, and repeated handling before the finished part reaches its required dimensions. Combining metal 3D printing with precision machining offers another approach: build material where it is needed, then cut the component to its final shape without moving it to a separate machine.

Japanese machine-tool manufacturer HORKOS CORP and Spanish metal additive manufacturing specialist Meltio have introduced a system designed around this principle. Their NX70 DUO version AM combines laser-based metal deposition with CNC machining in one integrated manufacturing center.

Reported by 3Druck on October 27, 2026, the launch highlights the growing interest in hybrid manufacturing for complex components, industrial repairs, and production environments where space and setup efficiency matter. The companies also reported that one machine had already been sold to an industrial customer.

Inside the HORKOS NX70 DUO Version AM

The NX70 DUO version AM is based on HORKOS’s NX70 1510B machining center. Its twin-head configuration and bedless structural design combine additive manufacturing and conventional material removal within one machine environment.

The system incorporates Meltio’s Wire-DED technology, short for wire-based Directed Energy Deposition. Instead of shaping a component entirely by removing material from a solid block, this process uses a laser to melt incoming metal wire and deposit material in selected areas.

Once the required material has been deposited, the machining capability can mill surfaces and features to the necessary dimensions. Depending on the component’s geometry, the operator can alternate between deposition and cutting rather than completing every additive operation before beginning all finishing work.

This integration is especially useful when a component requires material to be added in stages, with intermediate machining needed to reach surfaces that would otherwise become difficult to access. Keeping the workpiece in the same setup can also reduce the handling and repositioning associated with transferring it between separate machines.

Why Wire-Based Directed Energy Deposition Matters

Directed Energy Deposition is an additive manufacturing method in which concentrated energy melts material as it is placed onto a component. In Meltio’s system, the feedstock is metal welding wire, and laser energy creates the melt pool used to build the deposited structure.

Wire-based deposition is particularly relevant to industrial manufacturing because it can add material to an existing component or create a near-net-shape part for subsequent machining. Near-net shape means the deposited component is close to its intended final geometry but still requires finishing to achieve specified dimensions and surface quality.

Unlike a conventional CNC-only workflow, which typically removes material from a workpiece, the hybrid approach can add material before cutting it away where necessary. This can be useful when manufacturing a complicated shape would otherwise generate substantial machining waste or require specialized tooling.

However, additive deposition does not eliminate the need for engineering controls. Manufacturers still need to consider material compatibility, deposition quality, thermal effects, dimensional tolerances, and the machining allowance required for the final component.

The best results depend on choosing a suitable material and process plan before production begins. Engineers must determine which areas should be built through deposition, which surfaces require machining, and whether the combined workflow provides an advantage over established manufacturing methods.

Applications in Complex Components, Repair, and Remanufacturing

One application highlighted for the NX70 DUO version AM is the production of closed impellers. These rotating components are used in industrial equipment, including machinery that moves fluids, and can contain internal contours that are difficult to reach with conventional milling tools.

By combining deposition and machining, manufacturers can approach complex geometry in stages. The process may allow selected surfaces to be finished before additional material is deposited, depending on the design and accessibility requirements.

The machine is also intended for component repair and reconditioning. Rather than replacing an entire metal part because a particular area has worn down, a manufacturer may be able to deposit material onto the affected region and machine it back to the required dimensions.

Such an approach may be relevant to aerospace, energy, heavy industry, and other sectors where components can be expensive, geometrically complex, or difficult to replace. Whether repair is technically and economically appropriate depends on the component’s condition, material, service requirements, and inspection criteria.

Before selecting a hybrid manufacturing process, engineering teams should verify that the deposited material is suitable for the intended application and that the finished component can meet its mechanical, dimensional, and quality requirements. Critical components may also require material testing and additional inspection.

Space Efficiency and the Role of iMQL Technology

Factory floor space is an important consideration when production involves separate additive manufacturing equipment, CNC machines, and workpiece handling systems. Integrating multiple operations into one platform can reduce the need to move parts between manufacturing stations.

HORKOS uses its proprietary Non Bed Structure in the machine’s design. The underlying NX70 platform was developed to provide a compact arrangement while accommodating relatively large workpieces, although the overall space required by a complete installation also depends on tooling, safety provisions, material handling, and supporting equipment.

The machine also incorporates HORKOS’s water-soluble iMQL system for machining lubrication. Minimum quantity lubrication systems deliver controlled amounts of lubricant to the cutting process rather than relying on conventional high-volume coolant delivery.

The companies present these features as part of a broader effort to address production-space constraints, labor shortages, and environmental considerations. Actual improvements in operating costs, resource consumption, and productivity will depend on the manufacturing application and how the equipment is integrated into the facility.

Frequently Asked Questions About Hybrid CNC Machining

How is hybrid manufacturing different from conventional CNC machining?

Conventional CNC machining removes material to produce the required geometry. Hybrid manufacturing combines this subtractive process with additive deposition, allowing material to be added and then machined within an integrated workflow.

Can wire-based metal 3D printing repair existing parts?

It can be suitable for certain repair and reconditioning applications, provided the component material, damage, and service requirements are compatible with the deposition process. Inspection and machining are generally needed to verify the restored geometry and quality.

What should manufacturers evaluate before adopting a hybrid machine?

Review the component geometry, material compatibility, required tolerances, deposition and machining cycle times, operator training, inspection procedures, maintenance needs, and total installation costs. Compare the proposed workflow with conventional manufacturing to establish whether integration provides a measurable benefit.

The NX70 DUO version AM was scheduled for exhibition at JIMTOF 2026, the Japan International Machine Tool Fair, at Tokyo Big Sight from October 26 to 31, 2026. The announced program included a machine dry run and video demonstrations of actual printing processes.

For manufacturers considering hybrid CNC machining, the next step is to evaluate a representative component and map out its complete production sequence. Comparing deposition requirements, finishing operations, quality controls, and handling time will help determine whether combining additive and subtractive manufacturing offers a practical advantage for the intended application.