Cold Metal Spray (CMS) technology is transforming the way industries repair, restore, protect, remanufacture and manufacture metallic components. At the centre of this development in the UK is the close relationship between Cold Metal Spray (Dycomet UK Ltd) and leading research organisations such as the University of Nottingham and TWI (The Welding Institute).
Together, they are helping to accelerate the adoption of cold metal spray technology across the aerospace, energy, marine, automotive and general engineering sectors.
From Dycomet Research to Real-World Application
Dycomet UK, now widely associated with the Cold Metal Spray brand, has specialised in the development of application services and the adoption of cold metal spray systems for many years. The company has played a significant role in introducing the technology to the UK and EU market, establishing itself as a service supplier that repairs, restores and adds protective coatings to an incredible range of metal components, while also supporting research, development and industrial applications.
Based on this extensive practical experience, the company created a specialist service division — Cold Metal Spray — focused on repair, coating and additive manufacturing solutions through cold spray technology and wider solution-engineering expertise. Cold Metal Spray operates what it describes as the UK's only purpose-built, dedicated cold spray workshop, offering both on- and off-site services as well as research and development support.
The Cold Spray Process
Cold spray differs fundamentally from conventional welding, thermal spray and other additive manufacturing methods. Rather than melting material, the process accelerates metallic powder particles to extremely high velocities using compressed gas. The particles impact the substrate at supersonic speeds and bond through kinetic energy, while remaining below their melting temperature.
Key Advantages
Cold Metal Spray's technology offers a number of important advantages:
- Corrosion, erosion and cavitation repair
- Minimal heat input and no distortion of the substrate
- Little negative effect from impurities
- Low porosity and high-density deposits
- Multi-metal matrix and bimetallic coatings
- No heat-affected zones (HAZ) and reduced oxidation
- Composite coatings with excellent adhesion
- Good conductivity
- No phase transformation within the material
- Reduced residual stresses and preservation of substrate properties
- Suitability for restoration, repair, coatings and additive manufacturing
- Portable operation at the customer's site or in the field
These characteristics make cold metal spray particularly attractive for repairing worn, corroded and damaged components, where traditional welding may introduce unacceptable thermal stresses.
Building Bridges Between Industry and Research
The relationship between Cold Metal Spray and research institutions reflects a broader trend in UK manufacturing: the integration of industrial capability with academic and applied research expertise. CMS has long promoted the practical industrial deployment of cold spray through application services, equipment development, demonstrations and application development, and has built a UK-based research facility where customers can evaluate the process for specialist applications.
Meanwhile, academic and industry institutions contribute to the scientific understanding and qualification frameworks required for wider adoption. By investigating deposition mechanisms, material behaviour and repair methodologies, these partnerships help establish the technical foundations necessary for certification and acceptance in highly regulated sectors such as aerospace and energy.
Driving Sustainable Manufacturing
One of the strongest arguments for cold spray is sustainability. Instead of replacing expensive components, CMS cold spray can restore them to service — extending component life, reducing material waste and lowering the environmental cost and downtime associated with manufacturing and fitting new parts.
The lower-pressure systems used are particularly effective in repair and maintenance operations, offering portable, flexible solutions that can be deployed close to the point of need. This aligns closely with modern manufacturing objectives focused on circular-economy principles and asset life extension.
Conclusion
The connection between Cold Metal Spray (Dycomet UK Ltd) and R&D represents a powerful combination of industrial expertise and research excellence. Dycomet UK has made low-pressure cold spray technology accessible to UK industry, while Cold Metal Spray demonstrates its real-world value through repair and coating services — with the scientific validation and technical authority that supports wider adoption across critical sectors. Together, they are helping position cold spray as one of the most important advanced manufacturing and repair technologies available in the UK today.