The Hybrid Additive Fertigungstechnik (HAFT) project, funded by the FHInvest 2016 programme (grant code 03FH016IN6) and led by Prof. Dr. Ralf Hellmann at Hochschule Aschaffenburg, delivered a fully integrated hybrid manufacturing platform that combines selective laser melting, high‑speed milling, and hot‑isostatic pressing (HIP). The core equipment is the Matsuura Lumex 25 system, which was purchased with minor technical adjustments to meet the project’s specific requirements. The HIP module was supplied by the Swedish company Quintus, the world leader in isostatic presses, and offers performance advantages over the originally specified press, such as higher pressure stability and faster cycle times. Together, these components enable the production of complex metal parts with superior dimensional accuracy and mechanical integrity, a capability that is particularly valuable for the medical implant market targeted by the project.

During the 18‑month master thesis that ran concurrently with the project, students investigated the influence of HIP parameters on the microstructure and mechanical properties of laser‑melted titanium alloys. Preliminary results show a significant reduction in residual stresses and an increase in tensile strength compared to parts that were only laser‑melted. These findings are being prepared for publication in a peer‑reviewed journal and will form the basis for future industrial collaborations. In addition, the hybrid system has been used for a series of proof‑of‑concept experiments, demonstrating the feasibility of producing patient‑specific implants with complex internal lattices that would be impossible to fabricate with conventional additive manufacturing alone.

The HAFT project has also had a substantial impact on the university’s research profile and educational offerings. A new interdisciplinary bachelor’s programme, WIMAT (Industrial Engineering with Materials Science), now includes a four‑semester course on additive manufacturing, while a two‑semester elective is offered to all engineering students. The project has attracted three doctoral candidates and four master students, all of whom are working on topics that build on the hybrid platform. The research activities have led to the establishment of a BayWiss consortium for doctoral training in cooperation with Friedrich-Alexander-Universität Erlangen‑Nürnberg, further strengthening the institution’s position in additive manufacturing research.

Collaboration has been a cornerstone of the project’s success. In 2018, a joint DFG grant proposal on hybrid additive manufacturing was submitted with the University of Bayreuth, and a manuscript based on the ongoing collaboration with the two chairs at Ruhr‑Universität Bochum is slated for submission to *Materials Science and Engineering A* later this year. The project also partners with TU Braunschweig on a joint effort to apply HIP to non‑metallic materials, and with the company PolyCrystal to explore industrial applications of the hybrid process. Regular meetings with medical clinics and orthopedic surgeons have already begun, laying the groundwork for future clinical trials of the produced implants.

Overall, the HAFT project has achieved its primary objectives of acquiring a hybrid manufacturing system, expanding research activities, and creating new academic programmes. The integration of laser melting, milling, and HIP has opened new avenues for high‑performance metal part production, while the extensive collaboration network has positioned Hochschule Aschaffenburg as a key player in the emerging field of hybrid additive manufacturing.