Revolutionizing Defense Manufacturing: Digital Sheet Metal Forming for Cold Spray Additive Production

Cold Spray Additive Manufacturing (CSAM) is a solid-state metal 3D printing process that builds parts by accelerating metal powders at supersonic speeds toward a substrate using a high-pressure gas jet. Unlike traditional additive manufacturing methods, Cold Spray doesn’t use heat to melt materials. Instead, the particles deform on impact and bond together, producing high-strength, corrosion-resistant parts with minimal distortion. This heat-free approach preserves the mechanical integrity and microstructure of the original material.

Cold spray technology offers a range of benefits for metal part manufacturing and restoration, including:

• No thermal distortion or residual stress, due to the absence of melting.

• Faster build speeds (up to 6 kg/hr) for large-scale or high-volume applications.

• Superior material properties like high density, tensile strength, and corrosion resistance.

• Ability to fuse dissimilar metals in a single component (e.g., steel-titanium hybrids).

• Eco-friendly: lower emissions, minimal material waste, and no toxic byproducts.

• Ideal for repair: Extend part lifespan by restoring worn surfaces without disassembly or heat damage.

Cold Spray is rapidly gaining traction in aerospace, defense, automotive, energy, and medical manufacturing due to its unique ability to produce large, durable, and precise metal parts without the drawbacks of heat-based manufacturing. It’s commonly used for:

• Ballistic protection and armor plating

• Aircraft and satellite component repair

• Corrosion-resistant coatings for oil & gas parts

• Biocompatible implant coatings

• Rapid tooling and large cylindrical structures

Absolutely. In fact, cold spray is one of the most effective technologies for remanufacturing and metal part repair. It can:

• Rebuild worn or eroded surfaces without thermal stress

• Restore original geometry and mechanical function

• Add wear-resistant or corrosion-resistant layers

• Avoid warping and microstructural damage caused by welding or thermal repair methods

This makes cold spray ideal for maintenance of legacy equipment and cost-effective remanufacturing.

Cold spray is compatible with a wide variety of metal powders and metal blends, including:

• Titanium and Ti-6Al-4V

• Aluminum alloys (e.g., 6061, 7075)

• Nickel-based alloys (Inconel 625, 718)

• Copper, silver, and precious metals

• Steel and stainless steel

• Tantalum, tungsten, and other refractory metals

• Composite blends and certain ceramics

Because the process doesn’t melt the material, it’s especially suited for difficult-to-form or thermally sensitive metals.

Yes — and not just in the “slap a leaf on it” way. Cold spray technology is a green alternative to traditional metal manufacturing due to:

• Near-zero material waste (only what’s deposited gets used)

• No toxic fumes or emissions

• No need for inert gas environments or high-energy lasers

• Extends the lifecycle of parts through efficient remanufacturing

• Reduced reliance on overseas supply chains for spares and repairs

If you’re trying to make your manufacturing operations more sustainable, cold spray is more than just buzzword-compliant—it’s actually effective.