2024 Year End Review

As 2024 comes to a close, we reflect on another year of success and growth. We are very proud of what our small team is able to accomplish. Here are some some stats:

Last year, on our WarpSPEE3D machine at Neighborhood 91 we had roughly:

• 662 Builds and sprays (not parts, builds)

• 298 Hours of spray time

• 291kg of build mass

• 569kg of material sprayed

• We processed 28 different alloys and blends, often multiple in a day, with many (9) of them from our neighbor Metal Powder Works.

• The highest efficiency was >98% deposition efficiency, the lowest was ~5%

• We processed in excess of 232 calibration and test builds while analyzing various material systems, powder cuts, and toolpath strategies.

• Across all of the different materials, PSDs, process parametrization, and experimentation, we still averaged ~1kg/hr build rate

• Our benchmark materials build from 70-98% efficiency and in many cases can meet their industry standard properties, including cast NAB (ASTM B148) and forged AA6061 (AMS 4127).

• We functionally graded a Ni-based alloy to a Ti-based alloy.

• We produced a multilayer composite.

• We performed several 'build on a build' prints, including dissimilar materials.

• In addition to builds, we processed numerous different coatings of dissimilar materials.

Outside of cold spray:

• Initial tungsten calibrations were performed on the Freemelt AB EB-PBF system at HAMR.

• We designed and collaborated on our first powder-DED component, with a big thank you to FormAlloy Technologies, Inc.!

• We printed numerous SLA and FDM prints for both fixturing and prototype components.