A consumable insert for welding a first component to a second component is provided. The first component is positioned with respect to the second component in such a manner that a gap is defined between adjacent surfaces thereof. The consumable insert includes a body having a profile. The profile of the body matches a scan of a profile of the gap between the adjacent surfaces. The consumable insert also includes a dam portion having a profile. The profile of the dam portion matches, at least in part, a scan of corresponding surfaces of the first component and the second component respectively. The dam portion is provided in contact with at least one end of the body. The dam portion is configured to control an overflow of a weld puddle therefrom. The body and the dam portion are formed using three dimensional printing.