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Relatively low dimensional accuracy and poor surface quality have been the major drawbacks for selective laser melting (SLM). A hybrid SLM and computer numerical control (CNC) milling system that operates in an alternating manner may have the capability of improving the dimensional accuracy and surface quality to a comparable level to conventional CNC processes. However, very few studies have been conducted on the machine development and experimental applications of this hybrid process. In this study, we developed a hybrid SLM/CNC milling system based on the fundamental understanding of the hybrid process. Key technological challenges are analyzed including the mechanical design of the hybrid machine to solve the design contradictions in hybridizing the two processes, the adaption of laser scanning system to avoid structural interferences between SLM and CNC, and the process planning …