What is near net shape powder-based manufacturing?

Near net shape manufacturing technologies produce components that are close to the finished size and shape, requiring a minimal amount of finishing process such as machining.  Such processes include closed die forging, investment casting, metal injection moulding and more recently Additive Layer Manufacturing (ALM).

Powder based manufacturing uses a powder feedstock which is densified by using electron beam, laser or electrical discharge; an example of such a technique would be ALM. Various materials can be processed in this way including metals, ceramics and polymers.

The principal advantages of such techniques are:

• A reduction in the number of processing steps
• Significant reduction in the amount of waste material generated
• The ability to easily produce intricate and complex geometries direct from  computer aided design (CAD) models
• Rapid design iterations and ease of part customisation
• The possibility of utilising materials that would otherwise be extremely difficult to process

Key industries already using these techniques include:

• Aerospace – engine and airframe components
• Bio-medical -  devices and implants
• Motorsport – weight critical components with high temperature requirements