Analysis of Manufacturing Process Selection Criteria Between Additive, Subtractive, and Hybrid Processes

This thesis presents a comprehensive analysis of the selection criteria between additive, subtractive, and hybrid manufacturing processes. As manufacturing technologies evolve, understanding the optimal choice of process based on economic, environmental, and technical factors becomes critical. The work is organized into four main sections. First, it introduces additive, subtractive, and hybrid manufacturing, with examples of techniques for each category. Next, it examines the key methods and criteria relevant for selecting one manufacturing process over another. The third section provides an analysis of 17 studies comparing additive and/or hybrid manufacturing to subtractive methods. Finally, it presents a synthesis highlighting common findings, differences, and unique insights drawn from the collected studies. The results indicate that selecting a manufacturing process depends on criteria like material efficiency, part complexity, and production volume. This research also highlights the unique strengths and limitations of each approach: additive manufacturing offers high material efficiency, subtractive manufacturing excels in precision and scalability for mass production, and hybrid manufacturing combines these advantages within a single workstation. Furthermore, the findings emphasize that additive manufacturing's environmental benefits are most significant for low-volume, high-complexity applications, while subtractive manufacturing remains advantageous for high-volume, simpler designs. In conclusion, while no one-size-fits-all solution exists, this study provides a framework for manufacturers to select processes aligned with specific design, sustainability, and economic priorities.