Unlike conventional PM, MIM, HIP-CIP, or PF, spray forming is not used to fabricate individual net-shape components. Rather, the process is used to produce semi-finished mill products in the form of billets, tubes, and sheet/plate.

The process consists of sequential stages of liquid metal atomization and droplet consolidation to produce a near-net-shape product. The as-sprayed material is close to full density with a fine, equiaxed grain structure, with mechanical properties that meet or exceed those of ingot-processed alloys.

Spray forming is known for its high rate of metal deposition, typically in the range of 0.5–5.0 lb./s. Commercial processing includes alloy steels, stainless steels, tool steels, superalloys, aluminum, and copper-base alloys.