The world of manufacturing is changing rapidly, and the lines between traditional CNC machining and newer technologies like additive manufacturing (AM) are blurring. As hybrid processes gain traction—where subtractive and additive techniques are used in the same workflow—workholding systems must adapt. The workholding solutions of the future won’t just secure parts; they’ll need to accommodate a wider range of materials, geometries, and processes that combine CNC machining with 3D printing, laser cladding, and other additive techniques.
This blog explores how workholding is evolving to meet the needs of hybrid machining, what challenges shops face, and how you can future-proof your workholding setup for the next generation of manufacturing.
The rise of hybrid manufacturing
Hybrid manufacturing combines both additive (3D printing) and subtractive processes within a single machine or workflow. For example, parts may be printed in metal and then finished using CNC machining for tighter tolerances. This process allows manufacturers to take advantage of the flexibility of additive manufacturing while still maintaining the precision and material characteristics of traditional machining.
However, combining two manufacturing techniques introduces unique workholding challenges. Parts may start out as rough metal prints that aren’t yet perfectly flat or dimensionally stable, requiring careful handling during both printing and finishing. The workholding systems must secure the part through both stages while keeping it accurate, even as the geometry changes during the additive process.
The workholding challenge in hybrid manufacturing
Traditional workholding systems—such as vices, clamps, and chucks—were designed with subtractive machining in mind. These systems rely on the part’s geometry and a solid, uniform surface to create a repeatable and stable clamping force. However, additive manufacturing often results in parts with irregular surfaces, varying densities, and unique geometries. This poses a challenge for traditional clamps and fixtures, which can’t always grip the part securely without introducing distortion or movement.
Key workholding challenges in hybrid manufacturing include:
- Irregular and unfinished surfaces
As parts are printed, they may have rough or uneven surfaces, including residual material from the printing process. This makes it harder to create a repeatable grip, which is critical for machining accuracy during the second stage of production. - Dimensional instability
Additive parts, especially metal ones, may undergo residual stress or warping as they cool or after post-processing. This means the part may change shape after it is clamped, which can lead to errors if not properly handled. - Multi-stage clamping
In hybrid manufacturing, parts are often clamped multiple times—once for printing and then again for finishing. Each clamping cycle has to be repeatable and stable enough to prevent misalignment or distortion across multiple operations.
How workholding must evolve for hybrid processes
To address these new challenges, workholding systems must evolve. The key is adaptability—the ability to handle a wider range of materials, part geometries, and manufacturing processes with precision and repeatability. Here are some ways the future of workholding will look different:
- Modular and flexible systems
As part geometries become more complex and varied, modular workholding systems will become more prevalent. These systems can be easily adapted to hold a wide range of parts by simply swapping out or repositioning clamping elements. Modular workholding also allows for better accommodation of additive features, such as overhangs or partial geometries, which may not fit traditional clamp designs.
A good example of this is the use of zero-point clamping systems, such as 3r systems, which allow for fast and precise re-clamping across various machines and setups. These systems are well-suited for hybrid workflows that require the part to move between additive and subtractive machines without losing alignment. - Adaptive clamping technologies
As additive manufacturing involves working with parts that might change shape during printing or cooling, the clamping system must adapt to these variations. Technologies like force-sensing clamps and vacuum or magnetic fixturing can automatically adjust the amount of clamping force applied to ensure the part stays secure while avoiding excessive force that could distort it. These systems will help minimize the impact of material variations and part inconsistencies. - Dynamic part handling for additive processes
In some hybrid setups, robotic arms or automated handling systems are used to move parts between machines. These robots will need workholding that is easy to manipulate and can accommodate various stages of the process. Robotic workholding systems must be able to adjust to a wide range of part sizes and weights and be integrated with the machine’s cycle to reduce downtime and ensure the part is positioned precisely for both additive and subtractive operations. - 3D-printed fixtures
One of the most innovative developments in workholding for hybrid manufacturing is the use of 3D-printed fixtures. These fixtures can be quickly designed and printed specifically for the part being produced. This approach allows for highly customized fixtures that fit the unique geometry of the printed part, reducing the need for multiple re-clamping or adjustments during machining. Printed fixtures also allow for more lightweight solutions, which is ideal for parts that require less physical force to hold in place.
The advantage here is the ability to design and produce fixtures that match the exact shape and size of the part, reducing setup time and improving overall precision.
How to future-proof your workholding system
To stay ahead of the curve and accommodate the growing use of hybrid manufacturing in your shop, here are some steps you can take to future-proof your workholding systems:
- Invest in modular and zero-point clamping solutions
Modular systems give you the flexibility to handle a wider variety of parts, making it easier to transition between additive and subtractive processes. Zero-point systems are particularly helpful in maintaining consistency across multiple machines, which is critical in hybrid workflows. - Consider the adaptability of your fixtures
As additive processes advance, your workholding systems must be able to handle parts that may not be flat or have standard geometries. Look for fixtures that can be easily adjusted or modified to accommodate non-traditional part shapes. - Explore 3D-printed fixtures
If your shop is moving into hybrid manufacturing, consider experimenting with 3D-printed fixtures. This technology allows for rapid prototyping and customization, giving you the ability to create part-specific fixtures that minimize distortion and increase efficiency. - Monitor the needs of automation
If your shop is adopting automation, ensure that your workholding is robot-friendly. This means having fixtures that are easy to pick up, clamp securely, and are designed to fit seamlessly into automated workflows.
Closing thought
The future of CNC Self Centering Vise will increasingly involve hybrid processes, where additive and subtractive techniques complement each other. To keep up, workholding systems must evolve from static solutions to adaptable, flexible, and precise systems that accommodate a wider range of geometries, materials, and processes. Whether it’s through modular designs, adaptive clamping, or 3D-printed fixtures, the workholding systems of tomorrow will be key to unlocking the full potential of hybrid manufacturing.