Impact Innovations develops Cold Spray copper with superior properties as-sprayed
April 2, 2025
Impact Innovations GmbH, Rattenkirchen, Germany, has developed a Cold Spray Additive Manufacturing process for copper that combines ductility, bonding strength and thermal conductivity directly in the as-sprayed condition, with no post-heat treatment required.
The deposited material delivers bulk-like mechanical properties without the need for thermal post-processing. Offering flexibility and strength in a single process, it is well-suited for thin and thick coatings, functional surfaces, gas-tight layers, and load-bearing parts.
The material specifications are as follows:
- Ductility: 20% – bending possible
- Bonding strength: > 90 MPa (TIR1 tested)
- Thermal conductivity: up to 368 W/mK
- Hardness: 107 HV
- Helium leak rate: < 1×10−7 mbar·l/s (gas tightness)
- Minimum coating thickness: < 50 μm
- Deposition rate: up to 25 kg/h
- No limit on maximum thickness
The new copper solution is expected to bring Cold Spray AM closer to wide-scale industrial implementation in high-performance sectors, such as energy, electronics, repair and structural manufacturing.
