The classical design and manufacturing paradigm in aerospace leads to high buy-to-fly ratio; almost 90% of the raw materials turned into scrap, even for costly, advanced engineering Ti-alloys. The DISTOPIA project will address this, distorting aerospace manufacturing boundaries by developing an automated, cost-efficient wire-fed DED AM manufacturing and repairing method – made possible using novel metallic wires with enhanced mechanical properties; combined with implementation of full digital twin model of the process. Cost will be significantly reduced two-fold; requiring only wire material as needed for part mass and by eliminating the requirement for stock – typically over 2 million spare parts across multiple aircraft designs. These savings will increase the global competitiveness of the European industry and support sustainable development goals.