Impact Innovations completes 10 Weeks of Cold Spray AM series
Impact Innovations GmbH, based in Rattenkirchen, Germany, has completed its ‘10 Weeks of Innovation’ campaign, a ten-part series posted on LinkedIn showcasing the company’s EvoCSII high-pressure Cold Spray Additive Manufacturing technology.
From aerospace repair and rocket combustion chambers to medical implants, hybrid heat sinks and advanced corrosion protection, each week highlighted how the company is moving its Cold Spray AM from lab scale to robust, industrial applications.
Week 1: ductility in the as-sprayed state (N₂)
Demonstrated high ductility directly in the as-sprayed state using nitrogen – without heat treatment or helium – across Cu 99.95%, CuCrZr, Al 99.95%, AA7050, AA6061, and Ni. This reportedly improves cohesive/adhesive strength, fatigue behaviour, and crack resistance for Additive Manufacturing builds.
Week 2: Additive Manufacturing rocket combustion chambers
High-pressure Cold Spray Additive Manufacturing of >250 kg CuCrZr/In625 demonstrates large-scale AM with high deposition rates and low porosity for space propulsion.
Week 3: C-103 Cold Spray Additive Manufacturing
In collaboration with VLM Robotics, Taniobis and COMTES, Impact Innovation confirmed the feasibility of using C-103 niobium alloy with nitrogen to produce next-generation spacecraft components via Cold Spray AM.
Week 4: Hybrid heat sinks, coolers & busbars
Cold Spray AM enables 6× better heat transfer by soldering IGBT modules directly to copper coatings on aluminium heat sinks, replacing the TIM material and enhancing reliability in high-power applications.
Week 5: Ti-porous coatings for bio implant applications
In cooperation with Wissenkraft Labs, Impact Innovations developed cold-sprayed Ti-porous coatings for dental, orthopaedic and spinal implants that exceed FDA guideline requirements for shear strength, fatigue and abrasion resistance.
Week 6: plasma-facing W/Ta coatings for fusion reactors
With the Max Planck Institute for Plasma Physics, Impact applied dense W/Ta coatings up to 2 mm on low-activation steel for Tokamak and Stellarator first walls.
Week 7: from infeasible to feasible materials
High-pressure, high-temperature Cold Spray Additive Manufacturing with powder pre-heater enables what Impact Innovations called ‘previously un-sprayable metals and innovative material’ combinations.
Week 8: composite coatings for wear resistance beyond brake emissions
Using its EvoCSII, Impact Innovations deposits metal–metal, metal–ceramic, and metal–polymer composites at sub-melting temperatures to create dense, durable wear-resistant layers; Euro 7 brake-emission reduction is one application noted by the company.
Week 9: advanced corrosion-resistant coatings
Nitrogen-based Cold Spray Additive Manufacturing produces dense 100–200 μm aluminium, nickel and titanium layers with good salt-spray performance and cost savings.
Week 10: repair solutions with Cold Spray Additive Manufacturing
Versatile standard, mobile and portable EvoCSII systems restore high-value parts. According to Impact, its CNC torque drive repair saved €24,000 and already runs for years.
www.impact-innovations.com
