A new collaboration supported by NASA is all about new frontiers in 3D manufacturing: the recent research is now applied in some of the most demanding environments in aerospace and propulsion systems.
The University of Utah, Penn State, and Colorado-based Elementum 3D have received funding through NASA’s Small Business Technology Transfer (STTR) Phase I program to advance cold spray additive manufacturing for high-temperature alloys. Scientists’ work focuses on improving how complex components, such as those used in rocket engines, are produced and repaired.
Cold spray additive manufacturing builds parts by accelerating metal particles at high speed to form dense structures. Unlike conventional methods, it minimizes heat damage and allows for more flexibility in part size and geometry. However, key scientific questions remain.
“One of the challenges is understanding how particles bond, deform, or rebound upon impact,” the team stated – these are the factors that directly influence performance in extreme conditions.
The project centers on GRX-810, a NASA-developed alloy designed to withstand high temperatures and oxidative environments. While the material has already demonstrated strong performance, researchers are now working to better understand how it behaves during the cold spray process.
At the University of Utah’s STARS Lab, led by Dr. Suhas Eswarappa Prameela, the team is using a Laser-Induced Particle Impact Test (LIPIT) system to study individual particle behavior. “Our strength lies in understanding the fundamental physics,” Prameela said. “Programs like STTR allow us to translate those insights into manufacturing-relevant knowledge.”
The team is currently combining expertise across institutions, aiming to map how processing conditions affect material performance. 3D manufacturing technologies have never been closer to reliable use in next-gen propulsion systems.
