Expert insights

Technology spotlight: how NMIS is using cold spray to unlock smarter, more sustainable repair solutions

In our latest Technology Spotlight, we explore how cold spray is helping tackle some of manufacturing’s biggest sustainability challenges. As industries move away from hazardous, energy-intensive legacy processes, cold spray is emerging as a high-performance alternative for repair, refurbishment, and remanufacture.

At the National Manufacturing Institute Scotland (NMIS), we're leading the way in cold spray R&D as part of our ReMake programme, supporting manufacturers to extend component life, reduce waste, and cut emissions, especially in high-integrity sectors like aerospace, energy, and transport.

Key Insights:

  • Cold spray deposits dense coatings without melting, avoiding heat damage and distortion—ideal for high-value parts.

  • It offers a sustainable alternative to electroplated hard chrome, which is being phased out due to environmental and health risks.

  • The process requires minimal surface preparation and no post-heat treatment, making it efficient and scalable.

  • NMIS used cold spray to develop a high-performance repair solution, supporting circular practices like remanufacturing and refurbishment.

  • With a large working volume, adaptable nozzles, and multi-material capability, NMIS cold spray facilities can handle parts up to 3 tonnes.

  • The technology enables tribological coatings, wear- and fatigue-resistant surfaces, and even large-scale additive manufacturing.

  • Ongoing work includes developing new materials, in-process monitoring, and an international standard for cold spray in repair and AM.

This work is helping unlock cold spray’s potential as a mainstream tool for circular manufacturing—one that reduces reliance on raw materials and keeps products in service for longer.

Read the full article here: Technology Spotlight – Cold Spray at NMIS