Convergent Manufacturing

Convergent manufacturing integrates multiple manufacturing processes—such as additive manufacturing (e.g., AFSD, WAAM, L-PBF, EBAM, and CSAM), subtractive machining, and metrology—into a unified, optimized workflow to enable capabilities that cannot be achieved through any single process alone. By strategically combining these technologies, complex components can be produced with improved performance, tighter tolerances, and reduced cost and lead time. Central to this approach is the coordination of process sequencing and parameter optimization through processing–microstructure–property relationships, supported by in-situ monitoring, computational modeling, and data-driven methods. Additive processes are used to rapidly build near-net shapes or deposit material where needed, while subtractive methods ensure dimensional accuracy and surface finish, and metrology enables real-time feedback and process control. This integrated framework allows for the efficient fabrication of multi-material and functionally graded components, reduces waste, and enhances manufacturability, ultimately providing a flexible and scalable pathway for advanced component production aligned with defense and industrial needs.