3031 DoD-wide Cold Spray Technology Roadmap

Roadmap instrumental in acceleration of Cold Spray adoption and guidance of future investment

For more than 20 years, the DoD has successfully used Cold Spray technology for repair applications across the Services.


Cold Spray is an established technology supporting operational readiness, maintenance, and sustainment across the Department of Defense (DoD). Development activities are relatively disparate, with close working relationships of participants preventing duplication.


To develop a DoD-integrated Cold Spray technology roadmap while identifying the current state, common needs and actions, technology investment gaps, and priorities. Army, Air Force, and Navy – along with contractors and research partners – have been developing and implementing Cold Spray technology for more than two decades. Throughout the early stages of implementation, Cold Spray demonstrated a reduction in maintenance materials and costs, while increasing readiness. DoD-wide awareness of ongoing and planned Cold Spray programs is critical to expanding its applications and benefits. The DoD integrated roadmap coordinates individual Service investments in Cold Spray technology, and communicates current needs and planned activities, while enhancing collaboration, streamlining efforts, and facilitating joint strategies.

Technical Approach

Commissioned by the Office of the Secretary of Defense (OSD), the National Center for Defense Manufacturing and Machining (NCDMM)/America Makes partnered with The Barnes Global Advisors (TBGA) to coordinate individual workshops with the Army, Air Force, and Navy (Naval Air Systems Command [NAVAIR], Naval Sea Systems Command [NAVSEA]). Workshop participants included Service-specific research and development, program engineering, and sustainment personnel.
Data gathered during the workshops was analyzed to determine individual Service status, needs, gaps, priorities, and future efforts. Service-specific data were compared, assessed, and compiled to develop the DoD-wide Cold Spray technology roadmap.


  • Formed the Roadmap Project Team.
  • Coordinated teleconferences, workshops, and other events.
  • Collected data from events to integrate all Service input.
  • Organized and mapped major activities, and confirmed that overlaps were DoD-wide priorities.
    • Standardized terminology to highlight common activities and unique areas.
    • Prioritized future activities focused on areas enabling collaboration to create the broadest DoD impact by mapping gaps to key service capabilities.
    • Drove consensus via face-to-face workshops, enabled brainstorming and large group discussions, and allowed opportunities for feedback and refinement.
  • Established a Cold Spray Integration Working Group (CSIWG) to drive a collaborative culture.
  • Developed (and maintain) a current, living web-based roadmap, including roadmaps of varying detail levels.
  • Recommended short-and long-term projects to advance the development and implementation of Cold Spray.
    • Initiated four short-term projects:
      Supply chain
    • Initiated four long-term projects:
      Training curricula
      Supply chain maturation
      NDT and QA development
      Integrated Computational Materials Engineering (ICME)

Project Participants

Project Principal

Other Project Participants

  • The Barnes Global Advisors

Public Participants

  • U.S. Department of Defense

Success Story

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