An innovative process combination of additive manufacturing and sheet bulk metal forming for manufacturing a functional hybrid part

•Combination of AM by PBF-LB and sheet bulk metal forming as a new approach for manufacturing hybrid functional components.•Prove of manufacturing near-net shape tooth geometry on a sheet metal by PBF-LB.•Identification of critical part areas for hybrid parts manufactured by PBF-LB and sheet bulk metal forming.•The analysis of geometry, material flow, metallographic structure and hardness, provides process and design understanding.•Using the approach, part geometry is improved and flexibility increased compared to a conventional process chain