HYBRIDIA-Plus aims to accelerate the industrial adoption of intelligent and sustainable Hybrid Manufacturing (HM) solutions by seamlessly integrating conventional metal processes (casting and machining), Directed Energy Deposition (DED), post-processing, feedstock engineering, and AI-driven digitalisation. The project addresses key barriers limiting HM deployment in metal manufacturing SMEs and mid-caps, including process variability, limited productivity, insufficient digital integration, dependence on qualified feedstock, and the lack of operator-centric decision-support tools. HYBRIDIA-Plus will develop and validate fully integrated HM workflows supported by a unified digital architecture, explainable AI-based optimisation tools, and application-specific metallic powders, including circular routes based on recovering metal waste from the different processing operations. Industrial demonstrators for components based on critical or strategic raw materials, such as aluminium, copper and/or titanium, will validate the solutions at TRL 6–7, proving improvements in material efficiency, energy consumption, lead time and process robustness. By coupling advanced manufacturing technologies with human-centric AI and sustainable feedstock strategies, HYBRIDIA-Plus strengthens industrial competitiveness, resilience of metal value chains, and alignment with Industry 5.0 and EU sustainability objectives.