The implementation of additive manufacturing techniques in the production of mission critical structural components is challenged by its low throughput and limited build envelope. In recent years, hybrid production methods are emerging to bridge between the build volume and high throughput of conventional production methods and the design freedom enabled by additive manufacturing. The repeatability of material properties and the quality of the interface between the additive ma nufactured and wrought material are crucial for the adoption of hybrid manufacturing techniques by the industry. Here, the tensile behavior and fracture toughness of a hybrid Ti-6Al-4V alloy are examined in detail. Ti-6Al-4V pre-forms were built onto a wrought Ti-6Al-4V start-plate and extracted via milling. Compact tension and uniaxial tension specimens extracted from the hybrid pre -forms demonstrated good fracture and properties with no preference for crack growth in neither th e AM nor wrought materials. Microstructural characterization revealed a 40 mm transition layer into the wrought material which ends abruptly with no evidence of a gradually decaying heat-affected zone. The hybrid manufacturing approach studied here expands the current limitations of large -scale critical components with fine features and allow such structures to be produced with a higher throughput . Keywords: Additive manufacturing, Hybrid manufacturing, Fracture -toughness, Powder bed 2 1. Introduction Titanium and its alloys pose a unique combination of physical and mechanical properties such as high specific strength, high toughness, good corrosion resistance [1–6], etc. As such, Titanium alloys are often found in damage -critical load -bearing structures and weight critical products. Among the various Titanium alloys, Ti -6Al-4V stands out as being one of the most frequently used Titanium alloys in the industry. It i s not a surprise then, that with the emergence of additive manufacturing (AM) techniques, Ti -6Al-4V was one of the first metallic material to be incorporated into a commercial critical component [7]. Throughout the development of AM technology, Ti -6Al-4V was studied extensively in the scientific literature [8–17] as well as by aerospace and BioMed industries. Over the last decade, Ti -6Al-4V was intensively integrated into various additive manufacturing processes, demonstrating remarkable business case reasoning through improved functionality, efficient material usage, and cost reduction. Powder bed additive manufacturing is considered to be a low throughput manufacturing method, with a limited build envelope, thus landing itself mostly for the production of high -quality structures with fine features, very thin walls, lattice structures, fine internal channels, and cavities. In recent years, Hybrid AM - conventional manufacturing processes are emerging as a viable way to overcome the build limitations of AM, thus enhancing the functionally and expanding reach of the AM technology [18,19] . Hybrid manufacturing processes pose a significant technological advance, allowing for component repairs [20–23], production of bi - materials [24–28], and manufacturing of large components with intricate designs [29–33]. Hybrid manufacturing techniques, consisting of both powder bed fusion and wire arc AM hold a promise to result in a manufacturing method which marks the benefits of both worlds, i.e. relative freedom of design along with rapid manufacturing process [34] With the growing interest in AM of metallic components, the mechanical properties resulting from various powder bed and direct energy deposition techniques have been extensively studied in the literature. As can be observed from [35,36] and