Near Net Shape (NNS) manufacturing aims to produce components close to their final shape to reduce material usage, machining steps, and production costs. NNS processes include centrifugal casting and investment casting. Choosing an NNS process involves assessing the technological feasibility through analytical and experimental methods and performing a differential cost and feasibility analysis to compare the costs of the existing and proposed NNS processes. A case study on valve cages found that replacing conventional machining with an NNS process significantly reduced material and machining costs.

1. Introduction
Near Net Shape (NNS) is a generic term
given to manufacturing processes that aim to
produce products which are close to the final
produce products which are close to the final
shape and material of the component.
e.g. Centrifugal Casting
Often the judgement is qualitative rather than
quantitative.
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Foundry
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NIAMT
Ranchi
For assessing the technological and economic
feasibility of product several studies are done.
e.g. Differential Cost and Feasibility Analysis
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NIAMT
Ranchi

2. Near Net Shape Process
Near Net Shape (NNS) is a generic term given to
manufacturing processes that aim to produce
products which are close to the final shape of the
manufacturing processes that aim to produce
products which are close to the final shape of the
component.
e.g. Centrifugal Casting, Investment Casting.. etc
Department
of
Foundry
Technology,
NIAMT
Ranchi
Department
of
Foundry
Technology,
NIAMT
Ranchi

3. Advantages
• Material saving: Reduced material usage (saving
on procurement costs) & Reduced waste
on procurement costs) & Reduced waste
material (saving on recycle and waste disposal
costs)
• Energy efficient: Optimum utilization of Energy
• Reduced finishing steps (saving on production
time and costs, and reducing ‘wear and tear’ on
Department
of
Foundry
Technology,
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time and costs, and reducing ‘wear and tear’ on
machining equipment)
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4. Limitations
• Cost effectiveness for some products
• Properties requirement.
• Properties requirement.
Can be better defined seperately for each
process
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Technology,
NIAMT
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Department
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Foundry
Technology,
NIAMT
Ranchi

5. Application
• Turbine blades with complex shapes.
• Pressure Relief Valve Manufacturers In The Oil
• Pressure Relief Valve Manufacturers In The Oil
And Gas Industry, Aerospace, Power
Generation, Firearm, Automotive, Military.
• Cylinder Head, Connecting Rod, Engine Blocks.
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Foundry
Technology,
NIAMT
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Department
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Foundry
Technology,
NIAMT
Ranchi

6. Choosing a NNSP…
NNS is often a relative rather than an absolute
property.
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property.
Differential Cost and Feasibility Analysis (DCFA)
is done to assess the potential benefit of NNS
manufacturing process replacing a conventional
process.
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process.

7. Department
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Technology,
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Department
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Technology,
NIAMT
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8. Objective
Using the a NNS principles, a reduction of
machining (less material waste) and an
machining (less material waste) and an
increasing of raw material usage, economically
are the desired results of a new primary process
application that maintains at least the current
product quality as requirements (i.e. quality
improvement and collateral advantages can be
Department
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improvement and collateral advantages can be
achieved, but they are not the main objective).
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9. Technological & Economic feasibility
Technological feasibility (including its post-
process operation such as thermal treatments)
can initially be done analytically or numerically
can initially be done analytically or numerically
and then experimentally validated.
Economic feasibility has its main target is to
compare the cost differences between the old
and NNS manufacturing process from a holistic
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and NNS manufacturing process from a holistic
view.
Department
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Foundry
Technology,
NIAMT
Ranchi

10. Case Study
Valve Cage
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The high percentage of material costs in the final
component together with extensive machining required
for the bigger sizes made this component ideal for a NNS
study.
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Technology,
NIAMT
Ranchi

11. Department
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Department
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12. The Comparative Analysis
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Department
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13. The Comparative Analysis
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Department
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Technology,
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