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Additive Manufacturing

Metal part production via additive manufacturing process

Increasing Profit and Reducing Waste

UDRI offers a variety of capabilities and research services in additive manufacturing (AM), commonly referred to as 3D printing. AM uses a computer-driven printer to deposit layers of polymer, metal, or other media – from the bottom up – to create simple or intricate objects, as dictated by a three-dimensional, digital design file of the object. AM can be used in sustainment operations to print spare parts as needed or to create very large tooling and molds for traditional forms of manufacturing.

Top: Sparks fly as a metal part is produced via the additive manufacturing process. Image credit: UDRI/Dale Jackson


  • Advanced, Printable Composites - UDRI performs R&D in advanced, printable composites, specifically to help reduce the time and cost of manufacturing composite structures for aircraft.
  • Cold Spray Repair Technologies - UDRI offers expertise in this solid state metal surface repair technology, allowing the repair of high-dollar assets in a fraction of the typical lead time and cost.
  • Computer-Based Models - UDRI develops models that allow manufacturers to better predict the cost of developing a printed part, which can be difficult for small- and mid-sized businesses.
  • Integration of AM into Production - Small- to mid-size manufacturers are often unsure how to adopt additive manufacturing. UDRI helps create a “recipe” including development and analysis of materials and sample parts, production trial runs, and quality control data collection.
  • Manufacturing Tooling - Our researchers develop advanced additive manufacturing processes that produce complex geometry tools at a fraction of the cost of conventionally machined metal tools.
  • Materials Optimization - UDRI has experience in characterizing powder for creating build parameters leading to optimized material performance.
  • Printed Metals - UDRI has in depth experience in designing parts for AM, printing in a myriad of powders such as 17-4 stainless steel, titanium, aluminum, and nickel-based alloys, and developing innovative solutions to minimize residual stress.
  • Printed Polymers - UDRI has the capability to print standard polymers such as ABS, nylon, and Ultem® (polyetherimide), as well as advanced polymers.
  • Product Development - UDRI has the capability to perform new product design or reverse engineering of products via 3D digitization and geometric analysis, 3D printing of hardware and prototype models, and computer design and optimization of components, molds, and tools.
  • Training - UDRI offers education and training to provide technicians and engineers with the tools and mindset to maximize the potential of AM and Cold Spray.

  • UDRI's AM Capabilities at ATTC Dayton
  • This video shows our capabilities in additive manufacturing as currently applied in the Advanced Technology and Training Center (ATTC) at UDRI's Curran Place.

    AM Technology Development

    UDRI designs, analyzes, builds, tests, transitions, integrates and sustains groundbreaking technologies in additive manufacturing.

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    AM Quality Inspection

    UDRI tests the effect of various materials and process variables; we also study process monitoring and the development of process control schemes.

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    Cold Spray Repair Technologies

    UDRI supports and enhances cold spray technologies to provide customers with sustainment improvement and mission readiness.

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    University of Dayton Research Institute

    300 College Park
    Dayton, Ohio 45469 - 7759

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