Double-sided incremental forming (DSIF) and metal additive manufacturing (MAM) are one of the most flexible processes that do not require geometry-specific tooling for producing customized and complex metal parts. Synergistic hybridization of DSIF and wire-arc direct energy deposition (WDED) offers a promising approach to enhance product complexity. In this hybrid approach, non-planar substrates are formed using DSIF, while planar and/or non-planar deposition is carried out using WDED to fabricate components more efficiently and cost-effectively. Although this hybridization significantly reduces the need for support structures, critical aspects of surface quality and accuracy are not studied. Surface quality depends on bead profiles and distance between the adjacent beads. A methodology is developed and validated in the present work to predict overlap between two adjacent beads to minimize the variation in layer thickness considering process and geometrical parameters. Deposition on thin non-flat substrates results in significant geometrical variations due to thermal stresses resulting in component inaccuracies. Use of reconfigurable support is proposed to minimize the deformation of substrate during deposition and the same is validated. The effectiveness of the proposed methodology and the importance of use of reconfigurable support is demonstrated by successfully fabricating three different geometries using the Hybrid Deformation aided Additive Manufacturing (HyDAM). Results indicated that components fabricated using proposed overlap methodology and reconfigurable support have enhanced surface quality and better accuracy.