YOUNGSTOWN, Ohio – America Makes and the National Center for Defense Manufacturing and Machining announced a new project call worth a total of $920,000.

The High Priority Open Topics for Additive Manufacturing project, funded by the Office of the Under Secretary of Defense, Manufacturing Technology Office focuses on the development and maturation of additive manufacturing repairs for sustainment and beam shaping.

Additive manufacturing repairs for sustainment methods will include technologies such as directed energy deposition and cold spray. The beam shaping technology will focus on laser powder bed fusion processes. 

The project call consists of two topic areas, both concentrated on metals. Higher-level goals include developing and improving manufacturing technologies and processes to enable cost reduction, improving production speed and enhancing industrial capability that will be responsive to warfighter needs. A total of two awards are anticipated – one per topic area.

The project call reflects a focused, collaborative effort led by the America Makes Roadmap Advisory Group and its five working groups: Design, Process, Material, Value Chain and AM Genome. According to John Martin, additive manufacturing research director at America Makes, the groups met over two months to create and prioritize project topics. Based on survey results, the priorities were then shared with the Department of Defense’s Joint Additive Manufacturing Working Group, which selected key focus areas based on national defense and industrial needs.

“This structured engagement ensures the project call remains aligned with the most pressing needs and strategic opportunities in the additive manufacturing landscape, particularly those of critical importance to the defense sector,” Martin said.

The proposed projects should apply to Technology Readiness Level 4-7 and Manufacturing Readiness Level 4-7 at the onset of the proposed project.

The request for proposal is separated into two topic areas:

  • Topic 1 – AM Repairs for Sustainment: This topic seeks to advance additive manufacturing repair and surface engineering capabilities through the development and demonstration of qualified techniques, materials and technologies applicable to critical components across defense 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 2 – Beam Shaping: This topic focuses on developing consistent, certifiable printing processes that support future material qualification and standards development for high-performance applications. Technical approaches should include process parameter development, material characterization 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 defense 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,” Martin said. “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 defense and industry.”

The submission deadline is 5 p.m. July 15. For more information and to submit a proposal, click HERE.

A project kickoff webinar will be held at 2 p.m. May 27. For more information and to register, click HERE.

Awards are expected to be announced Aug. 15.