The geometrical accuracy of the hydro turbine runners is one of the most critical contributors to turbine performance, reliability, and eventually to the capacity utilization throughout its service life. However, achieving a high degree of accuracy in the runners of small hydro plants is challenging with conventional methods, due to their size limitations. This paper investigates the impact of the manufacturing of runners of small hydro plants using conventional casting methods on their performance. To address the limitation posed by the conventional method, the application of novel hybrid technology is explored, employing both additive and casting technology. The impact of both the conventional and the proposed hybrid technologies is compared through Computational Fluid Dynamics (CFD) analysis and experimental study. The test result with the conventional casting method shows approximately a 14% efficiency drop compared to the required (CFD), whereas with the hybrid technology, efficiency dropped approximately 1%.