About Us

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About Us

At U.S. Cold Spray, our vision is to revolutionize manufacturing and sustainment by advancing large-scale cold spray additive manufacturing and repair technologies. We strive to be the trusted U.S. leader in delivering production-ready structural and non-structural components that extend asset lifecycles, reduce costs, and strengthen supply chain resilience across aerospace, defense, maritime, energy, and industrial markets. By bridging research innovation with scalable production, we aim to empower our partners with sustainable, high-performance solutions that redefine what is possible in metal fabrication, coatings, and repair.

Our suite of cold spray technologies excels in joining dissimilar materials, producing high-performance coatings, and executing rapid, high-quality repairs that dramatically reduce component downtime. By minimizing energy consumption, turnaround time, and overall production costs, our cold spray solutions unlock a new paradigm of efficiency and sustainability in manufacturing.

U.S. Cold Spray's innovations in tribological coatings, corrosion-resistant materials, and structural component restoration directly support mission-critical needs across aerospace, defense, maritime, energy, and industrial markets. Through this work, U.S. Cold Spray strengthens U.S. manufacturing capabilities and supply chain resilience while delivering production-ready solutions that extend asset lifespans, lower sustainment costs, and empower our customers and partners to achieve next-generation performance in fabrication and repair.

With a suite of advanced cold spray manufacturing technologies, we are not just advancing additive manufacturing; we are revolutionizing the future of sustainment and production with precision, scalability, and trust.

02 Our Team

U.S. Cold Spray's Metals & Additive Manufacturing team consists of Master’s and Ph.D. level engineers and materials scientists with 20+ years of combined experience in cold spray, manufacturing, and failure analysis. Our team is prepared to advance our customers’ solutions from conceptual design through prototyping, testing, and small-scale production.

Dr. Bryer Sousa – Focus Area Lead, Senior Engineer

Dr. Jack Grubbs – Project Engineer

Dr. Christopher Massar – Project Engineer

G Fitzpatrick-Schmidt – Staff Engineer

Please click HERE to see a list of our patents, publications, and conference posters/presentations.

At Triton Systems, the parent company of U.S. Cold Spray, true innovation emerges at the intersection of multiple disciplines. Our Metals & Additive Manufacturing team collaborates closely with various focus areas to accelerate product development, optimize material performance, and create integrated solutions tailored to industry needs. Below are key related focus areas where joint efforts at TSI drive breakthrough applications across industries:

Applied Computational Engineering – Optimizing cold spray deposition by applying predictive modeling and simulation tools, driving refinements in processing strategies and controlling material behavior.
Composites – Fabricating multi-material structures that combine metals with lightweight composites for enhanced durability, mechanical performance, and weight savings.
Structures – Enhancing structural integrity and performance for aerospace, defense, and industrial applications.
Materials & Chemistry – Advancing powder feedstock development, surface treatments, and material characterization for wear resistance, corrosion protection, friction control, and thermal management.
Sustainment – Applying cold spray repair and refurbishment to extend lifecycles of critical components, reduce waste, and minimize environmental impacts.
Oceans Systems – Investigating marine applications of additive manufacturing, including corrosion-resistant coatings for ships and offshore structures.

Interested in partnering with our Metals & Additive Manufacturing team? Reach out to us below or via email at coldspray@tritonsys.com.

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Facilities & Equipment

U.S. Cold Spray's ~11,000 sq ft Cold Spray & Metals Processing Innovation Center consists of a suite of materials processing and analytical capabilities to provide our customers with high-performance, high-quality coatings, repairs, and near-net-shaped parts. Our Metal & Additive Manufacturing team currently leverages the following fabrication, post-processing, and quality assurance equipment:

High-Pressure Cold Spray System
Medium-Pressure Cold Spray System
Low-Pressure Cold Spray System
PLX Benchtop Plastometer & HotPIP Systems
Post-processing: heat treatment, light machining, etc.
Testing & analysis: sample preparation, metrology, microscopy, nondestructive evaluation

U.S. Cold Spray and Triton Systems also possess advanced modeling capabilities that support our materials processing initiatives:

TRACE Simulation.

Interested in learning more about our capabilities?

Contact Us

Ready to partner with us? Contact us today.