The article provides a comprehensive technical and economic assessment of additive, subtractive, and hybrid manufacturing technologies for producing complex-profile mechanical engineering products. The present study focuses on determining the optimal technological approach in terms of accuracy, structural integrity, material efficiency, and production cost. The analysis is based on a systematic comparison of key processes, including Powder Bed Fusion, Directed Energy Deposition, and CNC machining, which considers their capabilities for forming intricate geometries, internal channels, lattice structures, and functionally graded materials. The review synthesises industrial case studies from the aerospace, medical, and automotive sectors, demonstrating the efficacy of hybrid manufacturing, which integrates near-net-shape additive fabrication with high-precision subtractive finishing. This integration has been shown to result in a reduction of material waste by up to 70–80%, a decrease in production cycles by 30–50%, and a significant enhancement of mechanical performance through post-processing steps, such as hot isostatic pressing, heat treatment, and CNC finishing. The findings demonstrate that hybrid technologies facilitate the attainment of high-dimensional accuracy and surface quality, while preserving the design freedom characteristic of additive methods. The novelty of the research lies in the proposal of a unified decision-making framework for selecting a manufacturing strategy based on production volume, geometric complexity, material type, and economic feasibility. This approach provides a structured methodology that supports the implementation of hybrid systems in high-value, high-precision industries where traditional methods are either insufficient or economically impractical.
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