We offer three main Hybrid technologies; two use diode lasers as the power source and one uses gas metal arc welding (MIG) as the power source. The laser solutions are available with either wire or metal powder as the feedstock and the gas metal arc uses welding wire. These three Hybrid solutions are classified as Wire Arc, Laser-Wire, and Laser-Powder. 

The main benefit of a Hybrid machine is the ability to perform additive and subtractive operations with a single part set-up. Hybrid manufacturing combines the productivity, precision, and surface finish of CNC machining with the geometric freedom of additive manufacturing. The result is less material waste and the ability to produce, repair, and modify parts previously not possible or more cost effectively. Furthermore, the ability to combine material types in a component can maximize strength and wear life while reducing overall cost. 

All of our Hybrid solutions are available exclusively on Haas CNC machines, new or retrofitted to existing machines. There is a very large range of Haas vertical milling machines that can be integrated to become a Hybrid machine, from small TM tool room mills, to any of the VF vertical mills, to VM mold machines, and to most of the UMC universal milling machines. Hybrids are available for 3-axis, or 4-5 axis with rotary or trunnion. Phillips has been selling Haas machines for 40 years and is the largest Haas dealer worldwide. Our applications engineers can guide you to the best Haas and Hybrid solution depending on your part sizes, materials to be processed, applications and budget. 

There is a very large range of material types that can be processed on Hybrid machines.  Depending on the power source and if the feedstock is welding wire or metal powder, material types that can be processed include carbon and stainless steels, nickel based alloys, tool steels, aluminum alloys, titanium, tungsten, copper alloys, as well as specialty blended alloys. Practically any material type that is available in welding wire or in metal powder can be processed by one of our Hybrids. Please consult with our application engineers for recommendations for the best Hybrid solution for your particular range of materials. 

Both wire and metal powder are popular feedstock choices for Hybrid machines. Some of the benefits of using wire are its relatively low cost, easy availability from many welding suppliers, almost 100% material utilization when being processed, and easy storage with little concern for temperature and humidity. Advantages of metal powder include the large range of material types that are available in powder, as well as the ability to blend different powders to develop specialty materials. Using fine metal powder allows for creating thin walls and complex geometries. Metal powders are also an excellent choice for high-resolution laser cladding of parts for corrosion and wear resistance. 

Wire arc allows for high material deposition rates at relatively low cost. Wire arc also makes it possible to deposit highly reflective materials such as aluminum and copper. Wire arc is a robust solution that utilizes a well–known process that can operate in harsher environments. Lasers allow for a smaller heat affected zone which results in less part distortion and better material properties. Lasers require laser safe glass which is not as dark as the glass to protect the operator from arc flash and thereby provides better visibility of the workpiece being processed. With wire arc cameras inside the machine and a CCTV monitor by the machine control gives the operator visibility of the work in process. 

To program a part on a Hybrid machine, a CAM software package with additive programming capability is needed. Phillips supports many CAM software suppliers including Mastercam with APlus, Siemens NX, Autocad Fusion 360, Autodesk Powermill, Esprit, GibbsCAM, and Hypermill. At Phillips we primarily use Mastercam with the APlus plug-in. The CAM software programs the part for both additive and subtractive operations. 

To achieve the required tolerances, overbuilding of the part is typically done during the additive process, followed by machining to achieve the desired size and surface finish. To remove fully printed parts from the build plate, a bandsaw or wire EDM can be used. Heat treatment can also be required depending on the internal stress of the material, how much welding material was deposited, and the required hardness post welding. 

To operate a Hybrid machine, CNC machining experience is most advantageous. If you have a 5-axis Hybrid, 4 and 5-axis machining knowledge is valuable. For additive operations, any welding experience has value. Also, any part programming or use of CAM software will be of value. Phillips offers two weeks of on-site training in machining, additive and programming with each Hybrid machine. The training is tailored to the customer’s skill level; customized training is also available as needed. 

After the initial purchase, the operating costs for a Hybrid are quite low. The main operating costs are the selected feedstock, either welding wire or metal powders, and the shielding gas (typically Argon). There are some low–cost consumables such as deposition nozzles and the normal cutting tools for machining. 

At Phillips we are truly committed to your success. This starts with the initial evaluation process of your applications to determine the best machine model and size and best suited additive process and options to meet your needs. Our applications team takes full control of the end-to-end integration process. The integration is normally done on customer site to minimize machine down time and shipping costs. We have a highly skilled and trained team in both machining and additive to provide training and support in order for you to fully utilize Hybrid technology. A two–week training program at customer site is offered with each Hybrid machine and is available for up to 5 operators. Additional and customized training is also available on request. One year warranty comes standard with each Hybrid machine; additional warranty and multi-year maintenance packages are also available. Our wide service network is committed to providing rapid expert support during and after the warranty period.