Worcester Polytechnic Institute (WPI) has secured $6.3 million in funding from the Defense Advanced Research Projects Agency (DARPA) for a groundbreaking initiative set to transform additive manufacturing. The project, aptly named “Rubble to Rockets,” aims to enable the rapid production of high-quality components from scrap metal, even in environments with limited access to traditional supply chains, such as battlefields or remote disaster zones.
This next-gen approach integrates materials science, AI, and 3D printing. While conventional methods require thoroughly controlled materials, “Rubble to Rockets” uses a machine learning framework to identify and understand how diverse materials, such as mixed alloys and scrap metal, react and bond before being melted and 3D-printed.
“This work is crucial as it allows us to build high-quality components from unknown source materials with new confidence,” said lead researcher Danielle Cote. “Our goal is not just to build a single solution but to create a framework that guides future innovations.” The team will leverage AI technology from Citrine Informatics to predict material behavior, streamlining characterization for faster, more durable production. A proof-of-concept sounding rocket will test structural integrity.
Beyond defense, the technology offers promise for energy, transportation, and disaster relief. The project also emphasizes workforce development, with WPI collaborating with subcontractors including Siemens, Nightshade Corporation, and WPI alumni-led companies Solvus Global and VALIS Insights. Aaron Birt, CEO of Solvus Global, said, “This is one of those rare opportunities that demonstrates the breadth of technical expertise required to deliver a solution for manufacturing at the point of need anywhere on Earth, the moon, or beyond.”
The project, involving Associate Professor Danielle Cote and assistant research professor Kyle Tsaknopoulos, along with students, is expected to conclude in November 2027.
