GEN IV High Pressure Cold Spray System

GEN IV

Precision. Power. Performance.

The VRC GEN IV High-Pressure Cold Spray System represents the pinnacle of cold spray engineering. Built for maximum throughput, precision, and versatility, GEN IV delivers structural, high-strength coatings that approach the properties of wrought materials, making it the system of choice for mission-critical repairs.

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Why Choose the VRC GEN IV?

Structural Performance
  • Operates at up to 1000 PSI for metallurgical bonds near wrought material strength
  • Coatings 2–10× stronger than low-pressure or thermal spray alternatives.
  • Supports load-bearing structural repairs, not just surface restoration.
  • Proven in aerospace, defense, and heavy industry MRO environments.
No Heat-Affected Zone
  • Preserves base material integrity in heat-sensitive components.
  • Avoids grain growth or hardness loss from high-heat processes.
  • Perfect for thin-wall or precision parts with no warping.
  • Maintains tolerances, minimizing or eliminating post-machining.
Unlimited Deposition Thickness
  • Restore deep wear or damage to original dimensions without layer limits.
  • Create multi-layer coatings for combined resistance properties.
  • Reach target thickness faster, reducing operational downtime.
  • Rebuild complex geometries and machine to precise specifications.
Material Flexibility
  • Compatible with aluminum, titanium, steel, nickel, copper, and specialty alloys.
  • Bonds dissimilar metals without intermetallic formation.
  • Supports up to four simultaneous powder feeds for custom blends.
  • Tailored coatings for aerospace, maritime, heavy equipment, and more.
Environmentally Friendly
  • No toxic fumes—solid-state process avoids harmful emissions.
  • High deposit efficiency (>80%) and recyclable overspray materials.
  • Lower energy use than melting-based processes.
  • Enables repair over replacement, reducing waste and resource use.
Industry Proven
  • Aerospace & Military: Landing gear, gearbox housings, structural airframe components.
  • Energy Sector: Corrosion-resistant coatings for turbines, valves, and pipelines.
  • Heavy Equipment: Wear-resistant coatings for shafts, rotors, and gears.
  • Maritime: On-site hull, propeller, and pump restoration.

Industry Awards & Recognition

VRC Metal Systems is an award-winning leader in cold spray technology, recognized for innovation and excellence:

Lockheed Martin Exceptional Small Business Award

Inc. 5000 – Four-time honoree for fastest-growing private companies.

Defense Innovation Tech Connect Awards – Top 15% technology recognition for defense applications.

Veteran-Owned Business of the Year

Elevate Rapid City – Large Business of the Year.

The ROI of the GEN IV Cold Spray System

The VRC GEN IV is more than an equipment purchase—it’s an investment that delivers measurable returns across performance, operations, and sustainability. Here’s how companies see rapid payback and long-term value:

Reduced Downtime

Repair worn or corroded components to like-new condition, eliminating unnecessary replacements and extending service life.

Lower Replacement Costs

Extends the life of high-value components by restoring them to OEM specifications, eliminating the need for expensive replacements and avoiding long lead times.

Increased Throughput

Multi-powder feeder capability and rapid deposition rates allow more repairs and production runs in less time, boosting output without additional equipment purchases.

Lower Operational Costs

Efficient gas usage, minimal masking, and reduced post-processing translate to lower labor and material costs—improving margins on every job.

Our Services

Services to Support the GEN IV

Equipment Lease

VRC Metal Systems provides cold spray systems on a lease basis, which may be a more feasible approach for quick implementation.

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Friction Stir Welding

Discover how these leading-edge technologies can revolutionize your products by enhancing your product’s performance and lifespan.

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Integrated Installations

We can customize the perfect cold spray solution for your facility. If you have unique requirements, we can find a solution. Contact us today to get started.

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On-Site Support

We arrange for a system and operators to be at your location for a limited amount of time to help you get started with Cold Spray.

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System Callibration

System calibration and preventative maintenance are essential for ensuring that your cold spray system performs at peak capacity and efficiency.

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