Electron beam melting (EBM) is a relatively new direct-metal rapid manufacturing process that can be used to fabricate components with complex geometries and customized properties such as density, stiffness, etc. While most rapid manufacturing processes are near net shape processes, they invariably require finish machining to remove rough surfaces that can promote crack initiation. Since internal surfaces are inaccessible for finish machining, it is not always possible to take full advantage of the rapid manufacturing process capabilities. This is problematic for space-based fabrication where component weight reduction is particularly important. Accordingly, this talk will describe current efforts to improve the surface finish, accuracy, and material properties of metal parts produced via the EBM process.