Hybrid Manufacturing: Embedding Off-the-Shelf Components in 3D Printed Parts

Stronger and Smarter Builds

Wednesday 20th August 2025

Additive Manufacturing doesn’t have to work alone. One of the most powerful (and often overlooked) approaches for engineers is hybrid AM: embedding off-the-shelf components such as nuts, threaded inserts, bearings, bushings, magnets, and sensors directly into 3D printed parts during the print process.

It’s a clever way to merge the design freedom and geometric complexity capabilities of 3D printing with the precision of engineered components, allowing you to produce robust, functional end-use tools and parts without secondary assembly steps or added fixtures.

Not all AM technologies have this functionality enabled. Here we use the Markforged range of industrial 3D printers – designed and built for the factory floor. In particular, we use the Markforged FX10 and X7 composite printers.

Why Embed Components in Your 3D Prints?

✅ Reduce assembly time: By embedding off-the-shelf hardware during the build, you eliminate manual post-print installation of components, saving hours on repetitive assembly tasks

✅ Increase accuracy: Embedding bushings, linear bearings, or locating pins during the print improves alignment and positional accuracy for jigs, fixtures, and production tooling

✅ Enhance functionality: Add magnets for quick attachment, sensors for in-process monitoring, RFID tags for tracking, or electronics for smart tooling without complex assemblies, or additional costs

✅ Design for purpose: Create complex fixtures, strong load-bearing joints, or bespoke tools with exact-fit metal interfaces while keeping the benefits of lightweight, complex printed geometries

✅ Be cost and time efficient: By avoiding additional machining or custom tooling, you accelerate your workflow, reduce rework, and cut costs

Application Focus: Drill Guide with Embedded Bushings and Markings

In one of our recent in-house projects, we developed a bespoke drill guide to support a production workflow. The design featured:

• Embedded bushings: Standard drill bushings of varying sizes inserted and embedded during the print, providing precision alignment for repetitive drilling operations while withstanding wear from continuous use
• Identification markings: Identification and alignment sections were added in a contrasting yellow marker, mid-build using the pause function to improve operator clarity on the production floor
• Exact-fit ergonomics: The shape of the drill guide was contoured for the operator’s hand and the specific component it was drilling, reducing slipping and increasing throughput

The result? A repeatable, accurate drill guide built in under 24 hours, ready for use straight off the printer, without additional fixturing or machining, allowing the operator to focus on production rather than tool setup.

A light-weight precision tool with multiple drill holes ranging from 3mm to 10mm, used to guide fixings accurately on complex surfaces.

Ensures accurate hole placement specific to the designed component. Reduces risk of error, damage and high scrappage costs.

Onyx is non-marring, so guide does not damage surface during use.  

• Print time: 1 day 12 hours
• Part cost: £154.35

How We Embed Components During Printing

The manual process of embedding components itself its pretty straightforward, but work needs to be done in advance to the initial design, consideration to the orientation of the part and where pauses will be required. 

1. Design the cavity in your CAD to accommodate your chosen component with a snug fit.
Top Tip – we also recommend printing a thin shim to sit on top of your component, creating a flat surface against which the printer can continue to print once embedded. This shim can be added to your overall build, so it is on the build plate ready for when you need to use it.

2. Pause the print at the correct layer using your printer’s pause feature in Eiger. The key here is to look at the tool path layer-by-layer for your part, to ensure you add a pause at the correct height. One of the advantages of the Markforged range of printers over other FDM printers is setting the pause in the software. This automatically pauses the printer at the correct height, so you don't have to worry about standing nearby to "catch" the right moment.

3. When the machine pauses (it will also notify you), have your components ready to insert. Ensure it is seated correctly in the cavity, and add the shim (if required) before continuing.

Is Embedding Right for Your Process?

If you are:

• Making production jigs, fixtures, or gauges
• Producing one-off low-volume end-use parts with integrated hardware
• Seeking repeatability without complex post-processing

then embedding off-the-shelf components into your 3D prints can deliver significant workflow, cost, and quality advantages.

See Embedding in Action

Check out the short video above to get an understanding of the process.

We’ve also demonstrated these techniques in our previous Embedding Components Blog and our practical YouTube guide, showing how it works on real applications using the Markforged platforms.

Ready to Optimise your Workflow with Hybrid AM?

If you’re looking to explore hybrid AM capabilities or would like advice on how to implement component embedding in your workflow, contact us to discuss your project, or book a demo.

Explore how hybrid additive manufacturing can save you time, money, and headaches on your shop floor.