This study investigates the transformative potential of hybrid manufacturing, which combines additive manufacturing (AM) with conventional machining in producing industrial profiling knives for automobile body structures. By integrating standardized non-additive base plates with 3D-printed structures, hybrid manufacturing offers a novel approach to address challenges such as resource efficiency, cost reduction and design adaptability [1]. The hybrid process capitalizes on the strengths of both manufacturing methods. Conventional machining provides a robust and standardized foundation, while AM enables the production of complex, optimized geometries tailored to specific functional requirements [2]. This approach minimizes material waste by reducing machining volumes and allows for the rapid adaptation of designs to meet diverse operational demands. A fully automated digital workflow developed for this process includes segmentation into functional and non-functional areas, topology optimization, geometry reconstruction, and reanalysis of the resulting design. This automized workflow eliminates manual design effort and allows a fast generation of optimized tool geometries. This ensures an efficient integration of 3D-printed elements onto conventionally manufactured components, streamlining the production process. A key advantage of hybrid manufacturing is its ability to achieve significant cost savings while maintaining structural integrity and performance. By leveraging AM’s flexibility, manufacturers can adapt to varying design specifications and production scales, paving the way for modular and highly customizable solutions. Additionally, this method aligns with sustainability goals by optimizing resource usage and reducing material waste. This work highlights the potential of hybrid manufacturing to revolutionize precision engineering, demonstrating its applicability across various industrial sectors. By addressing economic and environmental challenges, the hybrid approach aligns with the objectives of advancing additive manufacturing technologies. Future research aims to refine automation in design processes further, explore diverse material combinations, and evaluate the long-term sustainability of hybrid production of tooling.