Hybrid CNC Parts expands laser-wire hybrid manufacturing with Haas and Meltio systems

Hybrid CNC Parts is significantly expanding its hybrid manufacturing: two additional Phillips Additive Hybrid Laser-Wire systems based on Haas machines increase the number of systems to three in total, tripling the available hybrid capacity. The company is targeting industries such as aerospace, defense and research, where repair, functional prototyping and small-batch production of nickel and cobalt superalloys like Inconel or Stellite, as well as tool steels, are in demand.

The Phillips systems combine a conventional CNC milling machine – such as a Haas VF-5 – with a mounted 1.2 kW IR laser head from Meltio that deposits wire material into the melt pool. This allows parts to be manufactured or repaired additively via laser-wire deposition and then finish-machined in the same setup. Especially compared with powder bed systems, there is no need for powder handling, dedicated safety rooms or depowdering. Founder Jesse Silverberg describes the company’s entry into the technology as follows:

“We first adopted the Phillips Additive Hybrid system after discovering Meltio’s laser-wire technology through Phillips,” said Jesse Silverberg, Ph.D., founder of Hybrid CNC Parts. “Seeing the system in person confirmed it could do exactly what we needed — deliver strong, machinable metal parts without the powder-handling challenges or constraints typical of traditional metal AM. Two and a half years later, we’ve proven the process, refined our metallurgical understanding, and are now scaling up to meet growing customer demand.”

In addition to its role as a contract manufacturer, Hybrid CNC Parts positions itself as an engineering service provider for “design for hybrid.” Designs are deliberately created so that additive and subtractive steps complement each other in a meaningful way, for example when locally building up functional zones or adding material to semi-finished products and existing parts.

“Designing for Hybrid requires a different mindset,” Silverberg added. “It’s not just about printing entire parts. It’s about knowing where to add material and where to machine — combining the strengths of both to achieve the best results. That’s where our experience really differentiates us.”

With the expanded fleet of two Haas VF-5 and one UMC-750 machines equipped with Meltio deposition units, not only throughput increases but also redundancy, for example for parallel development and production jobs. The company continues to be supported by Phillips Corporation, which handles integration and support.

“Hybrid CNC Parts is an excellent example of an early adopter who didn’t just implement the technology — they mastered it,” said Dan Insogna, Regional Account Manager for Additive Manufacturing at Phillips Corporation. “Their ability to design for Hybrid and deliver high-value, small-run production demonstrates exactly what this technology was built for: agility, efficiency, and innovation.”

Hybrid CNC Parts is now deliberately opening its expanded capacity to pilot projects and joint development programs. For companies that want to practically trial hybrid manufacturing with laser-wire deposition, a setup is now available that combines design, process know-how and machining-based post-processing within a single operation.

“Now that we’ve scaled our capacity and validated the process, we’re opening our doors to customers who want to see what Hybrid can do for them,” Silverberg said. “We’re ready to help others unlock the same advantages that have transformed our business.”