PARADDISE · Project

Hybrid 3D Printing Plus Machining That Cuts Metal Part Costs and Waste

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Imagine you could 3D-print a rough metal part with a laser, then precision-machine it on the same equipment — no moving between stations, no extra setups. That's what PARADDISE built: software, sensors, and controls that let one hybrid machine do both additive and subtractive work in a single run. They even developed a system to recycle the leftover metal powder so almost nothing goes to waste. The result is faster production of complex metal components using far less raw material than traditional machining alone.

By the numbers

consortium partners combining additive and subtractive manufacturing expertise

countries represented in the development consortium (DE, ES, FR, NO)

industrial partners validating the technology in real manufacturing contexts

total project deliverables including CAx software, sensors, and powder recycling

62%

industry participation ratio in the consortium

The business problem

What needed solving

Manufacturers of large, complex metal parts waste enormous amounts of expensive raw material through traditional subtractive machining — sometimes removing over 80% of the original metal block. Moving parts between separate 3D printing and machining stations adds setup time, alignment errors, and cost. Companies need a single-machine solution that deposits metal only where needed and finishes it to precision specs in one go.

The solution

What was built

The project delivered expert CAx software for hybrid process planning, optical sensor-based monitoring and control systems, and a metal powder recycling system. All components were integrated into the commercially available IBARMIA ZVH45/1600 Add+Process hybrid machine, creating a complete process-machine-tools solution for combined laser metal deposition and precision machining.

Audience

Who needs this

Aerospace component manufacturers machining expensive titanium or nickel alloy partsMold and die makers producing large tooling with long lead timesOil and gas equipment repair shops rebuilding worn high-value componentsHeavy machinery OEMs looking to reduce material waste on large metal partsContract manufacturers seeking to offer hybrid additive-subtractive services

Business applications

Who can put this to work

Aerospace components manufacturing

enterprise

Target: Manufacturers of turbine blades, structural brackets, or engine housings

If you are an aerospace parts maker dealing with expensive titanium or nickel alloy waste from traditional machining — this project developed a hybrid machine process combining laser metal deposition and precision milling in one setup, integrated into the commercially available IBARMIA ZVH45/1600 Add+Process machine. It includes monitoring, control systems, and a metal powder recycling system to minimize raw material loss on large, high-value components.

Oil and gas equipment maintenance

mid-size

Target: Companies that repair or remanufacture large metal components like valves, pump housings, or drill heads

If you are an equipment service company spending weeks waiting for replacement parts or shipping components between additive and machining shops — this project built CAx software and smart sensors that let you deposit metal exactly where worn parts need rebuilding, then machine them to spec on the same platform. The 8-partner consortium validated this on an industrial hybrid machine already on the market.

Heavy machinery and tooling

mid-size

Target: Mold and die makers or heavy equipment OEMs producing large metallic components

If you are a tooling manufacturer struggling with long lead times and high material costs for large molds or dies — this project created expert CAx technologies and optical sensor-based monitoring tailored for hybrid laser deposition plus milling. The solution was demonstrated on IBARMIA's commercial hybrid machine, with a metal powder recycling system that recovers unused material.

Frequently asked

Quick answers

What would it cost to adopt this hybrid manufacturing approach?

The project solution was integrated into the IBARMIA ZVH45/1600 Add+Process hybrid machine, which is commercially available. Exact pricing is not published in the project data, but costs depend on the machine purchase plus the PARADDISE software and sensor add-ons. Contact the consortium through SciTransfer for specific pricing.

Can this work at industrial production scale, not just in a lab?

Yes. The solution was specifically designed for large-scale manufacturing of value-added metallic components. It was integrated and validated on a full-size commercial hybrid machine (IBARMIA ZVH45/1600 Add+Process) that is already sold on the market, as well as at TECNALIA's industrial facilities.

Who owns the IP and how can I license the technology?

The consortium of 8 partners across 4 countries developed the IP under an EU Research and Innovation Action. Licensing terms would need to be negotiated with the relevant consortium members. SciTransfer can facilitate introductions to the right IP holders.

What specific components were delivered?

The project produced 7 deliverables including expert CAx technologies for hybrid process planning, smart monitoring and control systems with optical sensors, and a demonstrated metal powder recycling system. These were integrated as a complete process-machine-tools solution.

Is this compatible with our existing CNC equipment?

The demonstrated solution was integrated into a specific commercial platform — the IBARMIA ZVH45/1600 Add+Process hybrid machine. Based on available project data, adaptation to other machine platforms would require discussion with the consortium's technical partners.

What materials can this process handle?

The project focused on value-added metallic components using Laser Metal Deposition. While specific alloy lists are not detailed in the available data, LMD typically works with steel, titanium, nickel-based superalloys, and other weldable metals. The metal powder recycling system supports efficient material use.

How long has this technology been validated?

The project ran from October 2016 to November 2020 — over 4 years of development and testing. The hybrid machine platform existed commercially before the project started, and PARADDISE added the intelligent software, sensors, and process knowledge on top of it.

Consortium

Who built it

The PARADDISE consortium is strongly industry-oriented with 5 out of 8 partners (62%) coming from industry, complemented by 2 universities and 1 research organization across 4 countries (Germany, Spain, France, Norway). The coordinator, TECNALIA, is one of Europe's largest applied research centers and provided both project leadership and industrial testing facilities. Notably, machine manufacturer IBARMIA is a consortium partner, meaning the technology was developed directly with the company whose commercial machine it runs on — a strong signal that results can move to market. The geographic spread covers key European manufacturing hubs, which supports adoption across different industrial ecosystems.

FUNDACION TECNALIA RESEARCH & INNOVATIONCoordinator · ES
GKN AEROSPACE NORWAY ASparticipant · NO
RHEINISCH-WESTFAELISCHE TECHNISCHE HOCHSCHULE AACHENparticipant · DE
MANUFACTURE FRANCAISE DES PNEUMATIQUES MICHELINparticipant · FR
PRECITEC GMBH & CO KGparticipant · DE
UNIVERSIDAD DEL PAIS VASCO/ EUSKAL HERRIKO UNIBERTSITATEAparticipant · ES
SIEMENS AKTIENGESELLSCHAFTparticipant · DE

How to reach the team

FUNDACION TECNALIA RESEARCH & INNOVATION (Spain) — SciTransfer can arrange a direct introduction to the project coordinator and relevant technical leads.

Order a report on this consortium See FUNDACION TECNALIA RESEARCH & INNOVATION profile →

Next steps

Talk to the team behind this work.

Want to explore how hybrid additive-subtractive manufacturing could reduce your production costs and material waste? SciTransfer can connect you directly with the PARADDISE team and help evaluate fit for your specific components and production volumes.

Order a report on this topic More in Manufacturing & Industry 4.0