Review of hybrid additive–subtractive manufacturing of stainless steel for repair applications

Metal hybrid additive–subtractive manufacturing, a cutting-edge approach in modern manufacturing technology, enables a unified improvement in design flexibility and manufacturing accuracy by synergistically integrating the free-form capability of additive manufacturing (AM) with the precision machining advantages of subtractive manufacturing (SM). This technology demonstrates significant value, particularly in the fabrication and repair of complex stainless-steel components, overcoming the limitations of traditional processing of geometric configurations while ensuring dimensional accuracy and surface quality through subsequent finishing processes. This paper systematically reviews the latest research progress in metal hybrid additive–subtractive manufacturing, focusing on analyzing typical process methods and applicable material types. In response to application demands in fields such as aerospace, medical devices, and the automotive industry, this paper explores the potential of this technology in the manufacturing of stainless-steel components, as well as its current applications in remanufacturing and repair. Additionally, the two process forms of sequential and collaborative manufacturing are compared in depth, and the differences between the two modes were analyzed. Finally, future technological development trends are summarized and discussed.