The use of a plasma transferred arc welding torch as the high energy source for additive manufacturing results in several advantages vs. alternate high energy beams.  These advantages will be discussed and examples of demonstrated capabilities presented. For example, MER has produced billets of Ti-6Al-4V for Spirit AeroSystems for their testing to evaluate the PTA process for manufacturing of aircraft components.  In addition to the low cost fabrication of metallic structures, this technology has also been utilized to form very hard surface layers of a cermet composition which are functionally graded to the substrate.  These layers have excellent wear and corrosion resistance.  Graded composites have also been produced for structural applications.  In both the structural and coating applications, the gradation results in an exceptionally strong bond.  For the case of titanium alloys, a new very low cost approach will be discussed which utilizes a cold rolled “quasi” wire formed from Ti sponge and prealloyed Al-V powder.  High strength titanium foam has also been produced to near net shape and with in-situ skins for structures.