Modern manufacturing no longer relies on a single process to deliver high-performance parts. At MDA Ltd, we increasingly apply a hybrid manufacturing strategy – combining additive manufacturing (3D printing) with our advanced CNC machining services in Canada – to help customers achieve faster development cycles, tighter tolerances, reduced material waste, and lower overall production cost.
This approach allows us to leverage the design freedom of 3D printing and the precision, repeatability, and surface quality of CNC machining, creating parts that are not only innovative but also production-ready.
What Is Hybrid Manufacturing?
Hybrid manufacturing integrates additive and subtractive processes into one optimized production workflow:
- Additive Manufacturing (3D Printing) creates complex near-net shapes, internal features, and lightweight geometries.
- CNC Machining refines critical features – datums, bores, threads, sealing faces, bearing seats, and high-tolerance surfaces – to production specifications.
Rather than choosing between CNC machining or 3D printing, MDA Ltd applies both where each performs best.
Why MDA Ltd Uses Hybrid Manufacturing
1. Faster Product Development
Traditional development often requires:
- Custom tooling
- Long lead times
- Multiple design iterations with costly scrap
With hybrid manufacturing, MDA Ltd can:
- 3D print near-net prototypes quickly
- CNC finish functional features immediately
- Test, revise, and finalize designs without waiting on dedicated tooling
This dramatically shortens time from concept → validated part → production release.
2. Reduced Material Waste & Lower Cost
Conventional CNC machining frequently begins with an oversized billet, removing large volumes of material as chips.
Hybrid manufacturing reverses that model:
- The part is printed close to final shape
- CNC machining removes only the material required for precision surfaces
This results in:
- Lower raw material usage
- Reduced machining time
- Less tooling wear
- Significantly less scrap – especially important when working with high-value alloys
3. Superior Part Performance
Additive manufacturing enables:
- Internal cooling channels
- Lightweight lattice structures
- Consolidation of multiple parts into a single component
CNC machining ensures:
- Tight tolerances
- High surface finish
- Reliable mechanical interfaces
- Consistent repeatability for production
MDA Ltd’s hybrid approach delivers both engineering freedom and manufacturing reliability.
How MDA Ltd Executes a Hybrid Manufacturing Workflow
Step 1: Hybrid-Optimized Design Review
Our engineering team evaluates the CAD model to determine:
- Which features are best printed
- Which features must be machined
- Where machining allowances are required
- How the part will be fixtured and inspected
Step 2: Additive Manufacturing (Near-Net Shape Creation)
Using qualified additive processes, the part is produced close to final geometry, including internal structures that traditional machining cannot create efficiently.
Step 3: Stabilization & Post-Processing
Depending on material and application:
- Stress relief or heat treatment is applied
- Dimensional stabilization is performed prior to final machining
Step 4: Precision CNC Machining at MDA Ltd
Our CNC machining department then performs:
- Datum establishment
- High-tolerance machining
- Threading, boring, reaming
- Surface finishing
This stage transforms the printed blank into a production-ready component.
Step 5: Quality Inspection & Documentation
Every hybrid component follows MDA Ltd’s quality control protocols, including:
- CMM inspection
- First article inspection (FAI)
- Dimensional and surface verification
Where Hybrid Manufacturing Delivers the Most Value
Hybrid manufacturing is ideal for customers who need:
- Low-to-medium volume complex parts
- Rapid prototyping with production accuracy
- Lightweight or topology-optimized designs
- High-value materials (titanium, specialty steels, aluminum alloys)
- Frequent design updates or custom components
Industries served by MDA Ltd that benefit most:
- Industrial equipment
- Automation & robotics
- Energy systems
- Aerospace components
- Specialized machinery
Hybrid Manufacturing vs Traditional CNC Machining
| Requirement | Traditional CNC | Hybrid (MDA Ltd) |
| High design complexity | Limited | Excellent |
| Material efficiency | Moderate | High |
| Internal features | Difficult | Excellent |
| Time to prototype | Moderate | Fast |
| Production accuracy | Excellent | Excellent |
| Overall waste | Higher | Significantly reduced |
Why Canadian Manufacturers Choose MDA Ltd for Hybrid Projects
Customers work with MDA Ltd because we provide:
- Advanced CNC machining services in Canada
- Deep understanding of manufacturability
- Tight tolerance production finishing
- Proven quality systems
- Flexible prototype-to-production support
- Local supply chain reliability and fast turnaround
We help customers transition seamlessly from innovation to production.
Frequently Asked Questions
Can MDA Ltd machine customer-supplied 3D printed parts?
Yes. We routinely perform high-precision CNC finishing on customer-printed components.
Is hybrid manufacturing more expensive?
Not when part complexity is high or when material waste and development time are considered. In many cases, total project cost is significantly reduced.
Does hybrid manufacturing support production volumes?
Yes. Hybrid workflows can support both low-volume production and scalable manufacturing.
Next Step: Bring Your Design to MDA Ltd
If you are developing complex components and need both design freedom and production precision, MDA Ltd’s hybrid manufacturing capabilities provide a powerful competitive advantage.
Contact MDA Ltd today to discuss:
- CNC finishing for 3D printed parts
- Prototype-to-production machining strategies
- Material and tolerance optimization for hybrid manufacturing