Cold spray technology has been proven to have various engineering and manufacturing applications, including the capability to restore previously unrepairable parts. However, like most additively manufactured parts, it will likely require post-processing, such as machining, to improve surface finish and dimensional accuracy. In addition, cold spray deposits are typically porous. The porosity may be detrimental to the mechanical performance of the component. This paper presents a systematic evaluation of cold spray using readily available nitrogen as carrier gas, subsequent machining utilizing negative rake angle tools, and the effect of this novel hybrid fabrication method on subsurface porosity. The machining is optimized via finite element analysis (FEA) and the optimum is verified by experiments. The analysis informs the engineering of the proposed hybrid cold spray/machining method.