During machining the accumulated bulk stresses induced by previous process steps such as forging or additive manufacturing and subsequent heat treatment, are released. This causes undesirable distortion and geometry errors of the final component. These distortions are difficult to predict and, in practice, wide tolerances and several machining steps are applied to avoid reprocessing or, at worst, scrap. This project will develop an innovative hardware and software Toolkit to predict residual stresses prior to machining, estimate the distortions after machining due to the material removal process, and to optimize the machining process in order to minimize distortions. The outputs of this project will allow the industrial project partners to reduce scrapping and reworking, tighten geometric tolerances on components and minimize variations as well as increase component quality. This will increase competitiveness and save millions of Euros for the European manufacturing industry.