YOUNGSTOWN, OH — America Makes and the National Center for Defense Manufacturing and Machining (NCDMM) are proud to announce a new project call funded by the Office of the Under Secretary of Defense, Manufacturing Technology Office (OSD ManTech) worth a total of $920K. The project call, High Priority Open Topics for Additive Manufacturing (AM), focuses on the development and maturation of AM repairs for sustainment and beam shaping.
AM repairs for sustainment methods will include technologies such as directed energy deposition (DED) and cold spray. The beam shaping technology will focus on laser powder bed fusion (LPBF) 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).
This latest project call reflects a focused, collaborative effort led by the America Makes Roadmap Advisory Group (RMAG) and its five working groups: Design, Process, Material, Value Chain, and AM Genome. According to John Martin, AM Research Director at America Makes, these groups met over two months to generate and prioritize project topics. Based on survey results, the priorities were then shared with the Department of Defense’s Joint Additive Manufacturing Working Group (JAMWG), 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 noted.
America Makes strives to accelerate the development and deployment of innovative, cost-effective, energy-efficient AM technologies to meet defense and/or commercial needs. 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 High Priority Open Topics for AM request for proposal (RFP) is separated into two topic areas.
- Topic 1 – AM Repairs for Sustainment: This topic seeks to advance AM 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. 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,” said Martin.
Project call timeline:
- Launch: May 20, 2025
- Kickoff Webinar: May 27, 2025 (Registration Required HERE)
- Questions Due from Proposers about Scope or Approach: June 3, 2025
- Membership Eligibility Deadline: July 2, 2025
- Submission Deadline by 5 p.m. ET: July 15, 2025
- Anticipated Awards Announcement: August 15, 2025
Proposers for the project call are advised to reference the RFP for full details and guidelines HERE.