Alloyed Ltd has secured funding from the Aerospace Technology Institute (ATI) Programme for a £1m project to accelerate development of ABD-1000AM, a next-generation nickel-based superalloy designed specifically for additive manufacturing.

The project, delivered in collaboration with aircraft engine specialist ITP Aero and Cranfield University, aims to further enhance the material’s performance and manufacturing readiness. ABD-1000AM has been engineered to withstand the laser powder bed fusion process without cracking, overcoming a key challenge associated with high-temperature nickel alloys.

The material is expected to play an important role in future ultra-efficient jet engines, where complex, lightweight components must operate reliably in the extreme temperatures and harsh conditions found within combustion systems.

Support from the ATI Programme will help accelerate adoption of high-performance 3D-printed aerospace components and strengthen the UK’s position in advanced manufacturing technologies.

“Alloyed has been fortunate to partner with the ATI in several key technology areas, ranging from new material design to digital software platforms that support additive manufacturing adoption,” says Dr David Crudden, chief metallurgist and head of new market development at Alloyed. “ABD-1000AM is the world’s highest-temperature nickel-based superalloy designed for additive manufacture. We’ve identified significant demand for the material and believe it has the potential to be a game-changing technology for gas turbines in aerospace propulsion and industrial power generation.”

Cranfield University will contribute its expertise in high-temperature materials degradation and protective coatings, while ITP Aero will provide specialist knowledge in advanced combustor technologies for commercial and defence aviation applications.

Rob Mitchell, director of engineering at ITP Aero UK, says the project demonstrates the value of collaboration between academia, SMEs and industrial partners in shaping the future of aerospace technology and accelerating the development of next-generation propulsion systems.

More information www.alloyed.com

Aircraft operate in demanding environments that can compromise the integrity of wing skins. Corrosion remains one of the aviation sector’s most persistent and costly challenges, driving downtime, repeated maintenance interventions and disruption to operational schedules. Here, Calum Hicks (pictured), senior technologist at the Digital Factory, National Manufacturing Institute Scotland (NMIS), explains the importance of moving to cold spray application for wing skin repair. 

Traditional repair methods, including epoxy fillers and doubler plates, can extend component life through reinforcement and material replacement. However, these approaches often require ongoing repairs, limiting long-term efficiency. As modern aircraft are designed with strict safety requirements and low tolerance for material degradation, the industry needs a more durable and resilient approach to wing skin restoration.

Cold spray manufacturing offers that solution.

This additive manufacturing process rebuilds damaged components by accelerating metallic powder at supersonic speed to restore material without melting it. By replacing corroded areas with new aluminium alloy, cold spray restores wing skins to their original dimensions while providing a more corrosion-resistant and longer-lasting repair than conventional epoxy-based methods.

Unlike many additive manufacturing technologies, cold spray can be deployed directly inside maintenance hangars thanks to its low operating temperatures and portable equipment. This enables rapid access to damaged structures and significantly expands the scope of repairs that can be completed on-site. Corrosion-affected areas can often be restored within hours, compared with traditional methods that may require days due to preparation and curing times.

Cold spray also supports aviation sustainability goals. By restoring existing components rather than replacing them, the process reduces material waste and extends service life, helping to lower the environmental impact of maintenance activities.

More information www.nmis.scot