Near-net-shape manufacturing produces components that are very close to their final geometry, requiring only minimal finishing operations. This contrasts with subtractive manufacturing from billet, where significant material is machined away.

Near-net-shape is a key value proposition for large-scale metal AM processes like WAAM:

• Material savings: Buy-to-fly ratios improve from 10:1+ (machining from billet) to 1.5:1-3:1
• Reduced machining time: Only finishing cuts required
• Faster lead times: No waiting for forgings or castings
• Design flexibility: Complex internal features possible

The trade-off is that AM parts require post-processing to achieve final tolerances and surface finish.

• Typical Buy-to-Fly (WAAM) 1.5:1 to 3:1
• Typical Buy-to-Fly (Machining) 10:1 to 30:1
• Post-processing Required CNC machining, surface finishing

• Buy-to-Fly Ratio
• Wire Arc Additive Manufacturing