Novel all-in-one machines, robots and systems for affordable, worldwide and lifetime Distributed 3D hybrid manufacturing and repair operations


The 4D Hybrid main objective is to develop a new concept of hybrid additive manufacturing based on the modular integration of compact, low-cost modules including laser source, deposition head, sensors and control.

The 4D Hybrid technology enables unprecedented possibilities to exploit the potential of AM techniques: the same certified process may be used in different places/phases of product’s lifecycle: for initial production, for defective parts inspection/recovery, for in-situ repairing operations.

We are shaping the interaction between operators and the interfaces of the modules to avoid human errors and cognitive overload. The human-centered design approach allows creating solutions helping people to work better and safer, considering the complex and even harsh working conditions.



A preliminary LCA has been prepared considering the carbon footprint of 4D Hybrid industrial initiative. The focus is on possible savings in primary raw materials, number of roundtrip necessary to inspect repair parts and processing coming from the new application cases enabled by 4D Hybrid.



tons/year of metal raw material saved


GJ/year of energy saved


tons/year of CO2 reduction

By enabling the supply chain with fewer raw materials and less scrap, significant environmental benefits can be achieved. Additional advantages of 4D Hybrid concern the capability to realize a totally new generation of complex parts by reducing the number of sub-assemblies and manufacturing stages.

This leads to environmental benefits of reducing transportation, logistics and packaging where highly complex geometries can be constructed with one 4D Hybrid production step.

Moreover, because 4D Hybrid machine requires no tooling, manufacture can be undertaken nearer to the ultimate consumer, using a methodology known as “distributed manufacture”. The effect of both distributed manufacture and a leaner supply chain is a reduction in the need for haulage, warehousing, logistics and disposable packaging.

EU flagThis project has received funding from the European Union’s Horizon 2020 Research and Innovation programme under grant agreement No 723795.

sefriThis work was supported by the Swiss State Secretariat for Education, Research and Innovation (SERI) under contract number 16.0218.