Cold Spray Manufacturing | VRC Metal Systems | Box Elder, SD

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Repair and Replacements are Expensive

Cold Spray Is The Solution

Repair, restore, and enhance components without heat, distortion, or costly replacements.

Explore Cold Spray Solutions

Advantages of Cold Spray Technology

Cold spray technology offers several advantages, including the absence of a heat-affected zone (HAZ), which preserves material integrity during application. It enables structural strength repairs while significantly improving corrosion and wear resistance. Environmentally friendly and safe, this process supports advanced material versatility with high deposition efficiency and virtually unlimited coating thickness. Additionally, it produces minimal oxidation, ensuring high-quality, durable results.

What Is Cold Spray?

Cold spray, also called supersonic particle deposition, is a solid-state metal coating and repair process. Using a heated, high-pressure gas, fine metal powders are accelerated to supersonic speeds through a nozzle. When these particles impact a surface, they bond without melting, forming dense, high-strength coatings or restoring worn components to original dimensions.

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VRC Cold Spray

How Can Cold Spray Work For You?

Aerospace

Restore High-Value Aircraft Components Without Heat, Downtime, or Replacement Costs

Automotive

From production-line integration to mobile MRO solutions, we can help future-proof your operations.

Energy Sector

Restore critical assets faster, reduce downtime, and extend the service life of your key assets.

Heavy Equipment

The fast, safe, and cost-efficient solution – when uptime and equipment longevity are critical.

Liquid Handling Systems

In-place, precision restoration that eliminates downtime, heat damage, and costly part replacement.

Maritime

Rapid, In-place Restoration & Repair, Corrosion Control, and Maritime Asset Life Extension – Heat Free

Military & Defense

Maintain Critical Assets With Unmatched Speed, Precision, Safety, and Durability

Universities

Technology is revolutionizing how universities approach materials research

We are a global leader in applications to provide Cold Spray and development of advanced manufacturing technologies that provide the highest value to our customers.

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Awards and Certifications

VRC Metal Systems is proud to be recognized as an award-winning leader in cold spray innovation.

FAQ

What is cold spray technology?

Cold spray, also called supersonic particle deposition, is a solid-state process where fine metal powders are accelerated to supersonic speeds using a heated, high-pressure gas. The particles bond on impact without melting, forming dense, high-strength coatings or restoring components to their original dimensions.

How does cold spray compare to thermal spray?

Unlike thermal spray, cold spray does not melt materials. This means there’s no heat-affected zone, no oxidation, and stronger metallurgical bonds. Cold spray repairs are more durable, environmentally friendly, and preserve the base material integrity.

Which industries benefit from cold spray?

Cold spray is used across aerospace, defense, maritime, automotive, energy, and heavy equipment industries. It enables fast, safe, and cost-effective restoration of high-value components, minimizing downtime and extending equipment life.

What types of equipment does VRC manufacture?

VRC Metal Systems manufactures advanced high-pressure cold spray systems, including:

Gen IV (flagship system with advanced automation)
Raptor™ (rugged and portable)
Dragonfly™ (lightweight and man-portable)
C.A.M.P. Site™ (fully integrated mobile unit)
Brolga Series (trailerized expeditionary systems)

Why choose VRC Metal Systems?

VRC is an award-winning leader in cold spray innovation. We provide turnkey integration, global support, and reliable systems trusted by aerospace, defense, maritime, and heavy industry leaders.

About Us

We provide reliable metals deposition technologies, innovation solutions, and manufactured components to give our customers an unparalleled edge in the markets in which they operate.

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