America Makes announces AM Repairs for Sustainment and Beam Shaping project calls
May 22, 2025
America Makes, Youngstown, Ohio, and the US National Center for Defense Manufacturing (NCDMM) have announced a new project call worth $920,000: High Priority Open Topics for Additive Manufacturing. Funded by the Office of the Under Secretary of Defense, Manufacturing Technology Office (OSD ManTech), focuses on the development and maturation of AM repairs for sustainment and beam shaping as relates to metal.
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The proposed projects should apply to Technology Readiness and Manufacturing Readiness Levels 4-7 at the onset of the proposed project. The call is separated into two topic areas:
- Topic 1 – AM Repairs for Sustainment This topic seeks to advance AM repair and surface engineering capabilities through the development and demonstration of qualified techniques, materials, and technologies applicable to critical components across defence and industrial sectors. Emphasis will be placed on validating mechanical performance, process quality, and economic viability while engaging stakeholders to define qualification pathways, mitigate risks, and accelerate technology transition. Topic 1 covers technologies such as Directed Energy Deposition (DED) and Cold Spray AM.
- Topic 2 – Beam Shaping Focusing on Laser Beam Powder Bed Fusion (PBF-LB), Topic 2 focuses on developing consistent, certifiable processes that support future material qualification and standards development for high-performance applications. Technical approaches should include process parameter development, material characterisation, and documentation of process control, while considering post-processing needs and real-world implementation challenges. Engagement with stakeholders will be essential to identify qualification requirements, mitigate risks, and demonstrate the value proposition of beam shaping in defence and industrial applications.
“Through precise material deposition and ongoing research into standards for qualification and certification, AM repair is becoming a reliable, certifiable solution for high-performance applications. At the same time, innovations like beam shaping in laser Powder Bed Fusion are pushing the boundaries of print quality and efficiency, reducing defects, improving material performance, and enabling the use of more challenging materials. Together, these advancements are strengthening sustainment strategies and accelerating the broader adoption of AM across defence and industry,” stated John Martin, AM Research Director at America Makes.
Submission deadline for the High Priority Open Topics for Additive Manufacturing project call is July 15, 2025, with winners announced in August. Those interested can register for the kickoff webinar here.
