Abstract: A manufacturing method, including: given a predetermined finished part geometry, providing a sacrificial structure preform that simultaneously contains the finished part geometry, minimizes material that must be removed from the sacrificial structure preform to achieve the finished part geometry during machining, and has a sufficient stiffness to resist a machining force that will be applied during machining without allowing the finished part geometry to be compromised; and machining the sacrificial structure preform to achieve the finished part geometry. The manufacturing method also includes preliminarily estimating a stiffness of the finished part geometry and the machining force that will be applied during machining.

Abstract: A manufacturing method, including: given a predetermined finished part geometry, providing a sacrificial structure preform that simultaneously contains the finished part geometry, minimizes material that must be removed from the sacrificial structure preform to achieve the finished part geometry during machining, and has a sufficient stiffness to resist a machining force that will be applied during machining without allowing the finished part geometry to be compromised; and machining the sacrificial structure preform to achieve the finished part geometry.