Research & Development

Industry

Accelerate Innovation. Unlock Discovery.

Research and Development (R&D) teams face constant pressure to innovate, test new materials, and deliver cost-effective results. We provide high-pressure cold spray solutions engineered to help R&D organizations push the boundaries of material science, advanced manufacturing, and prototyping.

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Benefits of VRC Cold Spray Technology

Solid-State Bonding with Material Integrity

Because cold spray bonds metals without melting, repairs & coatings retain material fidelity - enabling R&D teams to explore advanced multi-material interfaces and high-performance, temperature-sensitive applications.

High Strength, Precision, & Unlimited Builds

VRC’s cold spray delivers bond strengths exceeding 40 ksi (~275 MPa) with porosity under 1%. Its supersonic particle beam offers fine precision and unlimited deposition thickness, making it ideal for prototypes, delicate repairs, and ultra-thick performance layers—all in one system.

Speed, Agility, & Minimal Prep

With rapid “shoot-and-start” operation, cold spray requires little surface prep, no masking, and no cooling time. This keeps R&D; workflows agile, enabling on-the-fly repairs and in-situ prototyping with minimal downtime.

Repeatable & Portable Solutions

Portable systems like the Gen IV, Raptor™, and Dragonfly™ reach tight spaces and deliver consistent, repeatable results across multiple repair cycles. Perfect for iterative testing, material exploration, and coating refinements without consuming base samples.

Proven Track Record in R&D

VRC is trusted by the Army, Navy, and major federal programs through multimillion-dollar contracts and STTR initiatives. In 2024, VRC launched the Dragonfly™, a modular in-field cold spray system now supporting aerospace, maritime, and energy applications—bridging lab innovation with real-world deployment.

Cold spray solutions for R&D

Our Equipment Options

Cold Spray

Dragonfly
  • Portability for for In-Place Repairs
  • Cost-Effective Maintenance & Sustainment
  • Quick Setup, Minimal Downtime
  • Ease of Use with Minimal Training
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Universities, Maritime, Military

Cold Spray

Brolga-002
  • Compact, Mobile System for Onsite Repairs
  • Optimized Plug-and-Play Design
  • Singularly Contained
  • Both Manual & Robotic Capabilities
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Universities, Universities, Military, Maritime

Cold Spray

Brolga-003
  • Fully Modular & Highly Deployable
  • Point-of-Need Trailerized Cold Spray Unit
  • Dual-Mode Operation: Robotic + Handheld
  • Rapid Setup & In-Field Adaptability
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Universities, Research, Military

Portable Dust Collector

Vark
  • Efficient, High-Volume Dust Extraction
  • Portable & Seamless Integration
  • Supports Highest Level Precision & Quality
  • Compact, Portable, and Facility-Friendly
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Research, Universities, Maritime, Military

Cold Spray

GEN IV
  • Multi-Powder Feeder for Material Versatility
  • Automated & Robotic Integration Ready
  • Precision Control for Cleanroom & High-Purity Standards
  • Reduced Downtime & Lifecycle Costs
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Research, Universities, Aerospace, Military

Cold Spray

C.A.M.P. Site
  • Fully Self-Contained, Mobile Manufacturing Unit
  • Lightning-Fast Component Repair
  • Both Robotic & Manual Applications
  • Deployable, Scalable, and Self-Sustaining
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Research, Universities, Maritime, Military

Cold Spray

Raptor
  • Structural-Grade Repairs with No Heat Distortion
  • Handheld or Robotic Application Ready
  • High-Deposition Performance for Large Components
  • Multi-Gas Compatibility & Data Logging
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Research, Universities, Maritime, Military

Cold Spray

Consumables
  • Precision-Matched to Your Equipment
  • Optimized Particle Size & Shape for Cold Spray
  • Backed by Data, Testing & Application Support
  • End-to-End Lifecycle Support
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Research, Universities, Aerospace, Military

Cold Spray

Additives
  • Supported by Application Expertise and Testing
  • Custom Blends for R&D Specific Solutions
  • Fully Optimized for High-Pressure Cold Spray Systems
  • Cost-Effective, Sustainable Waste Reduction
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Research, Universities, Aerospace, Military

Our Services

We Have Services to Support You

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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FAQ

Cold spray system calibration ensures optimal spray quality, coating adhesion, and deposition efficiency. Regular calibration prevents performance drift, reduces material waste, and extends equipment life.