Process-level benchmarking of hybrid additive-subtractive manufacturing routes for aerospace structural components

A comprehensive benchmarking study of a critical aerospace component, the pickle fork derivative, has been performed by fabricating it using various additive-subtractive hybrid manufacturing process routes. The objective was to evaluate and compare the process capability, geometric fidelity, and hybrid manufacturability of emerging deposition and forging technologies for structural applications. The selected processes included wire arc additive manufacturing (WAAM), wire-laser directed energy deposition (DED), laser powder bed fusion ( L -PBF), powder-blown DED, additive friction stir deposition (AFSD), and agility Forging. Wrought 316 L stainless steel and Al 6061 parts were machined and served as baselines. Each preform was fabricated, scanned using structured light, and subsequently finish-machined following a standardized hybrid processing route to ensure consistent benchmarking. The results reveal distinct process-dependent characteristics in build resolution, surface integrity, and overbuild allowance, which directly influence subsequent machining requirements and achievable dimensional accuracy. Fusion-based processes such as L -PBF and laser wire-DED produced near-net geometries with minimal overbuild, whereas WAAM, AFSD, and agility forging exhibited higher material allowances due to coarser resolution, thermal distortion, and build volume limitations. Despite these variations, all preforms were successfully machined to achieve dimensional conformity with the target CAD geometry, demonstrating the compatibility of additive and hybrid approaches for structural part fabrication. Further, preliminary mechanical performance evaluations were performed for hardness, strength, and fatigue resistance. The study highlights the critical role of process selection and preform accuracy in optimizing hybrid manufacturing workflows, providing key insights for the integration of additive, subtractive, and forging processes in aerospace component production. • Presents process-level benchmarking of hybrid additive-subtractive routes for an aerospace pickle fork component. • Establishes a unified workflow integrating additive fabrication, scanning, and machining for consistent comparison. • Quantifies differences in geometric fidelity, overbuild, and manufacturability across multiple process classes. • Shows processes like L-PBF and wire-laser DED minimize machining through near-net-shape fabrication. • Reveals process-dependent behavior in 316L, with wire-laser DED showing superior fatigue strength despite higher porosity.