Airfoil last chance screen utilizing EDM and AFM

A method of manufacturing a last chance screen for an aircraft engine, the method comprising:

• forming an array of holes through a metal sheet with a wire electrode using electrical discharge machining, wherein:
• the array of holes comprises a plurality of holes;
• each hole of the plurality of holes extends from a first end to a second end;
• and
• each hole is surrounded by one or more wall sections such that the last chance screen is defined by the plurality of holes and the plurality of wall sections;
• shaping the first end of each hole by applying a flow of an abrasive flow medium to the array of holes in a first direction, such that the first end of each hole is widened by the flow of the abrasive flow medium and a portion of the wall section adjacent to the first end of each hole has a first convex curvature with respect to the hole;
• and
• shaping the second end of each hole by applying a flow of the abrasive flow medium to the array of holes in a second direction which is opposite to the first direction, such that the second end of each hole is widened by the flow of the abrasive flow medium and a portion of the wall section adjacent to the second end of each hole has a second convex curvature with respect to the hole;
• wherein shaping the first end of each hole and shaping the second end of each hole results in an airfoil-shaped cross-section of each wall section.