As an alternative to casting and forging, thermal sprayed coatings can be used to produce highly complex near net metallic components. This method of manufacturing, using ChamPro™ controlled atmosphere plasma spray, can be used to manufacture components of exotic alloys that are difficult to cast or forge.

Near net shape technology is also a candidate for rapid prototyping. The coating is sprayed onto a male or female mandrel to the desired thickness, released from the mandrel and final machining operations performed. For prototypes, this alleviates the need to produce an expensive investment mold and the expense of test pours.

ChamPro™ technology can produce coatings with high densities and low internal stresses that approach, if not equal, those of cast components. The wall thicknesses can be as thin as 0.25 mm (0.010 in.) to as thick as 50 mm (2 in.). The choice of materials is almost unlimited, including refractory metals and their alloys.