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About this Abstract
Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Strategies for Sustainable Cold Spray Additive Manufacturing
Author(s) Ronan Flynn, Ashton Lyon, Stephen Price, Kyle L. Tsaknopoulos, Danielle L. Cote
On-Site Speaker (Planned) Ronan Flynn
Abstract Scope Cold spray additive manufacturing (CSAM) provides a unique way to both repair and create parts in an efficient manner. An emphasis on improving the sustainability of CSAM helps mitigate environmental impacts while enhancing logistics and supply chain resilience. Here we discuss numerous avenues to consider throughout the CSAM process that have advantageous effects on these areas. First is the reuse and recycling of metal feedstock powders, a critical process especially in material systems where deposition efficiency is low. Then, use of AI and large language models (LLMs) are explored to improve process efficiency and powder characterization. Finally, carrier gas recovery and generation are considered, while supporting the development of alternative carrier gases and alloys with high nitrogen printability. Continuing research in CSAM with sustainability as a focal point will further acceptance of these practices.
Proceedings Inclusion? Planned: Post-meeting proceedings

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Conversation with Dave Bourell and David Leigh about the history of the SFF Symposium
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A Fracturing Witness Artifact for Real-Time Residual-Stress Sensing and Mechanical Property Correlation in Laser Powder Bed Fusion
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A Framework for Comparison of In-Situ and Finite Element Data in Wire-Arc Directed Energy Deposition
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A Framework for Energy-Efficient Repurposing of Retired Components Using Hybrid Additive–Subtractive Manufacturing
A Graph-Based Thermal History Simulation for Material Extrusion Additive Manufacturing
A Hybrid Additive Manufacturing Platform for the Development of Bespoke Mechatronic Devices In-Situ
A Neural ODE Approach for Thermomechanical Field Prediction in Directed Energy Deposition
A Neural ODE Approach for Thermomechanical Field Prediction in Directed Energy Deposition
A Rheological Approach to Measuring Cure Depth of Soft Photopolymers
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A Risk‑Informed Digital Twin Framework for Qualification of Metal Additive Manufacturing Processes
A Simplified Vision Framework for Feedstock Monitoring and Flow-Related Defect Prevention in Pellet and Flake Extrusion Systems
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A Variable Bead Geometry Approach for Improving Conformal Slicing in Wire Arc Additive Manufacturing
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Active Thermography of Laser-Powder Bed Fusion Additive Manufacturing 316 Stainless Steel
Adaptive Feedforward Control of Mass Flow Oscillations in Powder Blown Directed Energy Deposition
Adaptive Height Control for Improved Geometry in Wire Arc Additive Manufacturing
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Additive Manufacturing of Titanium-Zirconium-Molybdenum Alloy Using Electron Beam Powder Bed Fusion
Additively Manufactured GRX-810 Alloy: The Influence of Build Interruptions on Microstructure, Tensile Strength and Fatigue Life
Advanced Manufacturing for National Security
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AI-Assisted Process Optimization for Multi-Material Thermoplastic 3D Printing and Charpy Impact Analysis
AI-Driven Robotic Forming of Sheet Metals: A Smart Manufacturing Approach for Defense Applications
An Improved Interlocking Pattern for Desktop Multi-Material Additive Manufacturing
An In-situ Test Artifact for Real-time Residual-Stress Monitoring and Mechanical Property Correlation in Laser Powder Bed Fusion
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Aperiodicity in Cellular Materials and the Missing Link: A Multiscale Statistical Analysis of Mechanical Behavior Using Meso-structural Quantification and Digital Image Correlation
Assembly-Aware Print Pose Optimization in 3D Printing for Multi-Robot Assembly
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Assessment of Manufacturing Process Variability in LP-DED JBK-75 Alloy for Structural Applications
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Characterization and Design of Digital Composites via Multi-Material Inkjet 3D Printing for Soft Tissue Replication
Characterization of Processing Defects in an AFSD Deposited 5xxx Aluminum Alloy
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Comparative Analysis on Traditional Manufacturing and Additive Manufacturing on Aluminum Matrix Alloy
Comparison of Micro-Tensile and Bulk Tensile Properties in the Directed Energy Deposited 316L Stainless Steel.
Cooling Rate Measurement in Laser Directed Energy Deposition Using an Event-based Camera
Coordinated Motion Control for Multi-Agent Wire Arc Additive Manufacturing of Non-Gravity Aligned Multi-Directional Components
Correlation Between Rheology, Print Quality, and Porosity in Robocasted Silicon Nitride Ceramics
Coupled Effects of Nozzle Diameter and Temperature on the Printability of Carbon Black/LIR Sensor Inks in Direct Ink Writing
Crack Reduction in L-PBF CM247LC using Shell and Core Build Style
Creating a Custom Optical Diagnostic for Advancing Liquid Metal Jetting
Cross-Printer Reproducibility Modeling Using a Deep Auto-Encoded Multi-Domain Gaussian Process
Decoupling Additive Manufacturing Tolerance from Nondestructive Evaluation Ultrasonic Resolution Using 3D-Printed Lithophanes
Decoupling Resolution and Throughput in Material Extrusion Additive Manufacturing
Defect-Oriented Risk and Monitoring Framework for Quality Assurance in Laser Powder Bed Fusion
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Design and Fabrication of Optimized Gyroid-Like Structures for Thermal and Mechanical Performance
Design of Interlocking Joints for Multi-Material Interface Using Topology Optimization
Designing & Printing Dispersion Strengthened Ti-6Al-4V via Laser Powder Bed Fusion Additive Manufacturing
Developing And Implementing Additively Manufactured Patterns For Sand Casting
Developing Rheology Modified Resins for Inkjet Printing of Dicyclopentadiene
Development and Characterization of Hybrid Nanocomposite Photocurable Resin for Vat Photopolymerization
Development and Validation of a Low-Cost Sensing System for Powder Dispersion Monitoring in Binder Jetting
Development of a Hot-Forging Wire-Arc Additive Manufacturing Tool
Development of a Thermal Characteristics Monitoring System for the Laser-Powder Directed Energy Deposition Process
Development of a Wire Directed Energy Deposition Worksheet for Identifying Additive Manufacturing Candidates
Development of an Eddy Current In-situ Diagnostic for Directed Energy Deposition
Development of an Inkjet Printing Process to Produce Interpenetrating Polymer Networks with Multiscale Heterogeneity for Additively Manufactured Electronics Applications
Development of Digital Twins in Additive Manufacturing
Development of Laser Based Modification Process for Water‑Atomized Powders for Additive Manufacturing Applications
Development of Multi-Laser Powder Bed Fusion Additive Manufacturing Testbed
Development of Wire-Fed Friction Stir Additive Manufacturing of AA 4043 on AA 6061 Using Conventional Knee Mill
Diffusion Study on Highly Porous 3D Printed Structures Made Using Vat Photopolymerization and In-Situ Phase Separation
Distortion Minimization In Deposition of Continuous Carbon Fibers On Non-Planar Surfaces
Domain Adapted Large Language Models for Additive Manufacturing
Dual-Component Direct Ink Write of Polyurethane Foams
Dynamic Layer Height Correction with Micro-Meander Tool Paths in 5-Axis Wire-DED
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Evaluation of Wire Arc AM Fabricated 316 L Stainless Steel Post Forging
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Experimental Evaluation of Unsupported Overhang Limits in Steel Parts Fabricated by Wire-Based Directed Energy Deposition
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Feedstock-Based Tungsten Modification of LPBF IN718 for High-Temperature Manufacturing Applications
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Flame-Retardant Bonded Magnetic Composites for Extrusion-Based 3D Printing
Flash Thermography for Thermal Diffusivity and Density Measurement of Cured Binder-Jet Samples in the Presence of Thermal Contact Resistance
From Defect to Feature: Controlled Porosity Patterning in Wire-Arc Directed Energy Deposition
Fused Deposition Modeling of Polyethylene/Boron Carbide Composites
G-Code-Aware Segmentation for Quality Monitoring in Direct Ink Writing
Generalizing the Computational Fluid Dynamics Imposed Finite Element Method (CIFEM) to Varied-Geometry, Multi-Layer Simulations of Laser Powder Bed Fusion
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Grain Morphology and Aging Response of Aheadd® CP1 Processed by Directed Energy Deposition.
Hardware-Constrained DMD Mask Optimization for Uniform Microscale Selective Laser Sintering of Copper Nanoparticle Films
Heating Rate–Driven Interfacial Stability in Cold-Sprayed SS316L on AISI 4140
Hierarchical Graph Neural Networks with Local Attention for Accelerated Part-Scale Scanwise Thermal Simulation in Laser Powder Bed Fusion
High-Performance PAEK-PEI Blends investigated Using Active-Filament Mixing Fabrication
High-Temperature Structural Integrity of Additively Manufactured Inconel 718 for Thermal Management Applications
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Hydroxyl-Functionalized MWCNT and Nanosilica Reinforced Photocurable Resins for Vat Polymerization
In-Situ Characterization of Residual Stresses in Powder-Based Directed Energy Deposition
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In-situ Dynamic Laser Area Heating in 450nm Diode Point Melting: Impacts on Microstructure and Surface Quality of SS316L
In-Situ Monitoring of the LPBF Process via MWP
In-Situ Qualification of Laser Power and Scan Speed via Melt Pool Emissions in Laser Powder Bed Fusion
In-Situ Surface Modification in Molten Metal Jetting
In-Situ Thermal Measurements of Multi-Pass and Multi-Layer Additive Friction Stir Deposition Builds
In-Situ Thermal Monitoring of the Laser-Powder Bed Fusion Process for Polyurethane-Modified Epoxy Thermosetting Polymer Networks
In Situ Synchrotron Radiography of Bubble Dynamics in Tungsten During Laser Powder Bed Fusion
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Influence of Droplet Parameters on Porosity in Metal Parts Manufactured with Droplet-On-Demand Metal Jetting
Influence of Elevated Chromium Levels on the Corrosion and Mechanical Behaviors of Directed Energy Deposited H13 Tool Steel
Influence of Gaussian and Ring Beam Energy Profiles on Melt Pool Morphology in Laser-Based Powder Bed Fusion of GRX-810 and 304 Stainless Steel
Influence of Porosity on Impact Toughness of Stainless Steel 316L Fabricated via Laser Powder Bed Fusion for Nuclear Applications
Influence of Process Parameters on Mechanical Strength and Durability of 3D Printed Concrete (3DPC)
Influence of Ultrasonic Vibration on Thermal Behavior and Solidification Characteristics in WAAM 316L Stainless Steel
Intellectual Property Protection in Distributed Intelligent Additive Manufacturing via Surrogate STL Generation and G-code Reconstruction
Investigating the Effect of Disturbances on the Dimensional Quality of Parts from Directed Energy Deposition(DED)
Investigating the Effect of Disturbances on the Dimensional Quality of Parts from Directed Energy Deposition(DED)
Investigating the Reliable Jetting of High-viscosity Polymers Using Piezo-driven Jet Valve
Investigation of Reduced-Order Temperature Models for Warpage Prediction in Composites Additive Manufacturing
Isotherm-Based and Heat Cycle Aware Thermal Monitoring and Prediction in Directed Energy Deposition
Joining Additive Manufactured 316L via Friction Welding: An In‑Situ Microtensile and Microstructural Evaluation
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LPBF CP1 Velo 3D – Ultrasonic Fatigue Testing (USF)
Machine Learning-Based Predictive Modeling for Geometric Distortion in Metal Material Extrusion
Magnetic and Mechanical Properties of SLA-based 3D-printed Magnetic Soft Composite Using a Halbach Cylinder for Inducing Anisotropy
Making it Snappier: Fast Pneumatic Actuation for Versatile Drop-on-demand Metal Jetting
Making the Impossible Possible via Multi-Modal, Multi-Material, and Multi-Axis Additive Manufacturing
Manufacturing Large Pressure Components with Multi Agent AM Systems
Measuring Natural Frequencies in a 6 DOF Industrial Robot Performing Additive Manufacturing Tasks Using Experimental Modal Analysis
Mechanical and Microstructural Effects of Interlayer Machining on Hybrid Wire Arc Additive Manufacturing-Processed Aluminum
Mechanical Behavior of As-Built IN718 Fabricated by Coaxial Laser Wire-Directed Energy Deposition
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Melt Pool Behavior, Microstructure and Mechanical Properties of Modulated Laser Powder Bed Fusion Processed Ti6Al4V
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Metal Viscous Thread Printing
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Microstructural Evolution during Additive Manufacturing of Functionally Graded Materials from Structural to Refractory Alloys: Integrated Computational-Experimental Framework
Microstructure–Corrosion Relationships in LPBF 316L Stainless Steel
Modeling Surface Roughness on Fatigue Performance of Additively Manufactured Ti-6Al-4V with Machine Learning
Modular, Non-Invasive In-Situ Monitoring of Laser Powder Bed Fusion Systems
Multi-Material Mixing Mechanisms Process Map
Multi-modal Foundational Thermal Model for LPBF Part Reconstruction
Multi-Nozzle Molten Metal Jetting for High Throughput Metal Additive Manufacturing
Multi-Objective Design Optimization of Auxetic Based Solid-Lattice Hybrid Structures for Additive Manufacturing
Multimodal In-Situ Monitoring of Laser-Based Directed Energy Deposition
Multimodal Non-Destructive Evaluation of Leak Behavior in LPBF 316L Stainless Steel Pipe Structures
Multiscale Computational Study of Laser Powder Bed Fusion Additive Manufacturing of Refractory TiTaNb Medium Entropy Alloy
Nondestructive Characterization of Heat and Print-Bonded Multi-Material FDM Interfaces
Nondestructive Characterization of Hybrid Ironed FFF-Printed PLA Parts
Nonlinear Graded Lattice Optimisation for Orthotropic Materials
Numerical Simulation of DLP 3D-Printed Photopolymers
Observation of Balling Defect Formation Mechanism in Laser Melting Using Synchroton X-Ray Radiography
One-To-Many Inverse Design of Curvy Strut-Based Lattices Using Mixture Density Networks
Optimization of SiC Powder Packing Through Bimodal Distribution and Mechanical Milling for Binder Jet Additive Manufacturing
Optimizing Cure Depth Measurements for Ceramic Vat Photopolymerization Industrial Applications
Optimizing Soft and Stretchable Elastomers for Vat Photopolymerization
Overcoming Z-Axis Anisotropy in FFF PEEK Components via Vacuum-Assisted Epoxy Infiltration
Oxides in Wire Arc Additive Manufacturing (WAAM): Effects on Build Quality, Mechanical Properties, and In-Process Mitigation Techniques
Panel Discussion: Navigating the Complexities of Advanced Manufacturing for National Security
Parametric Evaluation of Scaled Robocasted Alumina Architectures Under Controlled Processing Conditions
Parametric Workflow Design for Rotational Friction Welding of Complex Metal Additively Manufactured Geometries
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Physical Validation of a Threat Field-Based Online Planner for Multi-Robot Additive Manufacturing
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Physics-Informed Neural Operator for Thermal Modeling in Metal Additive Manufacturing
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Precision Density Control in Binder Jetted Composites via Selective Vacuum Infiltration
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Preliminary Experimental Results Using An Eight Nozzle Molten Metal Jetting Print Head
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Process Modeling and Design of Magnetoactive Elastomers in Reactive Extrusion Additive Manufacturing
Process Optimization for WAAM Deposition of High-Angle Unsupported Geometry Without Multi-Axis Positioning
Process Parameter Optimization for Overlapped Regions in Hybrid LP-DED
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Quantifying Airborne Particulate Dispersion in Binder Jetting 
Quantifying and Optimizing Part Adhesion in Liquid Metal Jetting
Quantifying Degree of Anisotropy in Polymer AM Parts
Quantifying Process Uncertainty in Laser Powder Bed Fusion: A Modeling Approach for Surface Topography Prediction
Quasi-Static and Dynamic Properties in Flexible Fused Filament Fabrication Polymers
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Real-Time Object Detection for Autonomous Robotic 3D Printing
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Residual Stress-Informed Slicing Optimization for Multi-Laser Powder Bed Fusion
Resolving Enclosed Internal Structures in Laser Powder Bed Fusion
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Robotic Reactive Extrusion AM for Large Scale Complex Geometry
RocketSmith: An Agentic System for High-Powered Rocket Design and Manufacturing
Room-Temperature Precipitation-Induced 3D Printing of PEEK with Tunable Porosity
Runtime-Reconfigurable RAPID Framework for ABB Arc-DED Systems
Segment-Resolved Probabilistic Defect Quantification in PBF-LB/M Single Scan Tracks Using µCT-Referenced Photodiode Features
Selective Laser Flash Sintering Using Scanning Fringing Field Electrodes in an Ionized Atmosphere
Sheet-Based Additive Manufacturing of Titanium Alloys Using Laser Pulse Integration of Sheets (LAPIS)
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Simulation-Aided Iterative Redesign for Laser Powder Bed Fusion Additive Manufacturing of a Complex Ti-6Al-4V Part
Sinusoidal Rosenthal Solutions for Design of AM Meltpool Feedback Control
Small-Scale Mechanical Characterization of LPBF-HIP GRX-810 for Rapid Qualification
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Spatial Heterogeneity of the Mechanical Properties in DLP 3D Printed Polymers
Spattering in Laser Powder Bed Fusion: Physics-based Simulations, Formation Mechanisms, and Reduction Strategies
Stable Multilayer VTP Tubular Structures
Strategies for Sustainable Cold Spray Additive Manufacturing
Structural Integrity and Manufacturability Benchmarking of a Generatively Topology-Optimized Component for Metal Additive Manufacturing
Study of Screw-Based Printing Using ABS Carbon Fiber on Planar and Non-Planer Surfaces
Symbolic Regression for Infrared Camera and Pyrometer Calibration in Wire-Arc Additive Manufacturing
Temperature Distributions of Traditional Deposition Trajectories Towards Thermal-Model-Informed Path Planning Strategies in WAAM
Temperature Gradient Mechanism-Based Approach to Reduce Warpage in Overhang Regions Using Beam Shaping in Laser-Based Powder Bed Fusion of AlSi10Mg at High Layer Thickness
Testing the Use of Various Minkowski Distances in Functional Grading of Multi-Material Additively Manufactured Origami-Based Mechanisms
The 10th Annual 3D Printed Aircraft Competition: Expanding the Scope of Student Learning Through Competition
Thermal Annealing-Induced Property Enhancement in Additively Manufactured PC-CF Composites
Thermal Modeling of Drop Placement Strategies for Multi-Nozzle Molten Metal Jetting
Thermal Optimization to Enable SMARTT Toolpaths for Efficient and Effective Multi-Robot DED
Thermal Simulation of WAAM Inconel 718 for Heat Accumulation and Process Stability
Thin Wall Microstructure and Mechanical Behavior of GRX-810 ODS Alloy Fabricated Across Multiple Laser Powder Bed Fusion Systems
Three Dimensional Semi-Analytical Thermo-Elasto-Plastic Solution for Additive Manufacturing
Topology-Dependent Mechanical Response of Gyroid and Triangular Lattice Infill in Metal Additive Manufacturing
Toward a Physics-Resolving Digital Twin for Metal AM: Graph Neural Network Surrogates for Thermomechanical Field Prediction and Sensor-Driven Defect Detection
Towards a Universal Scaling Law and Thermal Modeling Framework for Wetting Behavior in Laser Metal Additive Manufacturing
Towards Adaptive Heat Input in WAAM Processes
Towards Field Driven Design of Cellular Materials for Energy Absorption: Modeling and Simulation of Variable-Thickness Schwarz-P TPMS Structures
Towards Microstructure Control in Molten Metal Jetting Using Airborne Ultrasound
Towards SmartScan 3.0: A Scan Sequence Optimization Approach for Distortion Reduction in LPBF using Reduced-Order Thermo-Elasto-Plastic Models
Transient Thermal Modeling and Experimental Validation of WAAM-Fabricated 316L Stainless Steel Using Julia
Transparent Additively Manufactured Parts for Improved Mechanical Properties
Ultra-Compliant High-Density Bundle Structures: Formalization, Computational Design, Additive Manufacturing and Mechanical Behavior
Using Near-Net Shape Structures Printed by Fused Filament Fabrication to Characterize Tensile Property Anisotropy in Composite Polymers
Validation of Vision-Based Detection of Powder Spreading Defects in PBF-LB Using Light Scanning
Vision-Based Monitoring and Feedback Control for Laser-Wire Directed Energy Deposition
Volumetric Additive Repair: Near-Real Time Selective Multi-Axis Toolpathing
WAAM Development Cell with Adaptive Trajectory Control
Wetting Characteristics of Molten Titanium Particles Under Substrate Preheating in LPBF
Wire-Arc Additive Manufacturing Process Development for Martensitic Stainless Steels
Wire Arc Additive Manufacturing of Functionally Graded Materials
Wire Arc Additive Manufacturing of Layered HSLA–Stainless Steel Composite Structures for Enhanced Strength–Ductility Performance
Working Curve Model to Enable Precise Curing of Functionally Graded Resin Systems
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