A new solid-state deposition additive manufacturing process
Funded by the
European Innovation Council
About Us
Background
Additive manufacturing is the way of the future for creative design, eco-friendliness, and less material consumption. Metal additive manufacturing has brought about a radical transformation in product creation since its introduction to the market by providing greater design flexibility. However, low production rates and environmental limitations in thermal procedures pose challenges for mass production. On the other hand, cold spray, a solid-state additive manufacturing technique, is less adept at handling complex forms but provides greater material variety.
Problem
Significant limitations regarding material selection/combinations, part size, resolution, and production rate prevent the current AM processes from providing unique personalization. These AM techniques are incapable of meeting the sustainability standards and are defined by technological limitations that are no longer acceptable given the current trend. It is anticipated that closing these gaps will result in significant expansion of AM’s markets, applications, and efficiency.
Aim
To create a cutting-edge, new solid state AM technique based on the innovative idea of powder acceleration and charging in a specially designed electrostatic field. To enable the construction of multi-material structures with incredibly high precision and build rate, while also providing the unique capability of controlling single particles to concurrently and selectively cover a complete surface of nearly unlimited size.
Impact
It will lead the AM industry to unprecedented flexibility, scalability, and sustainability, as well as the unique ability to produce and repair future space structures because the process does not rely on gravity. This innovation promises excellent functional materials with different compositions and unmatched deposition rates.
People
Mario
Guagliano
Sara
Bagherifard
Amir
Lordejani
Monil
Thakkar
Rocco
Lupoi
Shuo
Yin
Pengfei
Yu
Ralf
Srama
Yanwei
Li
Marcel
Bauer
Nikolaos
Papakostas
Stephen
Redmond
Paulius
Gečys
Valdemar
Stankevič
Juozas
Dudutis
Edgaras
Markauskas
Miglė
Mackevičiūtė
Laimis
Zubauskas
Nan
Zhang
Rahul
Antony
News
Politecnico di Milano hosted kick-off meeting of the European Innovation Council-funded MADECOLD project. The meeting, held on June 18th, 2024, brought together an assembly of distinguished professors and researchers from some of Europe’s leading universities. The project, aimed at revolutionizing solid-state deposition through high-voltage electrostatic fields to accelerate and charge metal powder particles, has participation from University College Dublin, Trinity College Dublin, and the University of Stuttgart. The project aspires to enhance efficiency, reduce material consumption, and ensure the required accuracy for printing components…Read More
On February 4th, 2025, the Madecold consortium held its six-month (M6) Board and Management Meeting online. The researchers of the Consortium – Politecnico di Milano, University College Dublin, Trinity College Dublin and the University of Stuttgart came together to review progress and align on the next phase of this EU-funded project focused on the innovative electric-field assisted solid state deposition process.
The meeting opened with remarks from Project Coordinator Professor Mario Guagliano, followed by work package updates from each team. Progress was reported across technical tasks, with key deliverables on track. Dr. Paulius Gecys from FMTS – a prospective Hop-On partner, outlined their proposed idea for the micro-channel milling….Read More
Thanks to the opportunity offered by the Hop-On call HORIZON-WIDERA-2023-ACCESS-06, the Centre for Physical Science and Technology (FTMC), Lithuania, is the new partner of the MADECOLD Consortium. FTMC was contacted considering the advanced knowledge and expertise in the design and manufacturing of micrometric channels with the desired length, respected the tight geometrical tolerance needed for the MADECOLD launcher. This is what we need for completin…Read More
Monil Mihirbhai Thakkar, PhD student at Politecnico di Milano, presented his latest research at the Transcom 2025 Conference held from 21st to 23rd May 2025 in High Tatra Mountains, Slovakia. The presentation, titled “Metal Particle Acceleration To Supersonic Speed: Numerical Simulation And Preliminary Results”, showcased feasibility of LINAC-based particle acceleration and bonding…Read More
Exciting progress at the MADECOLD project!
On 2nd December 2025, consortium members gathered at the University of Stuttgart to discuss the latest developments in WP3 and to review the ongoing work on the LINAC (particle accelerator) system and Gate Control for LINAC….Read More