Kinetic Metallization

What is Kinetic Metallization?

Kinetic Metallization™ (KM) is an advanced solid-state additive manufacturing process used to deposit metals, plastics, and metal matrix composites onto a variety of substrates—including ceramics, plastics, glass, and especially metals. Unlike traditional thermal spray methods, KM operates below the thermal softening point of the feedstock, preventing melting and minimizing thermal distortion. This technique enables the application of high-performance coatings or the creation of freestanding shapes with superior material integrity.

How Kinetic Metallization Works

Instead of using heat, KM relies on high kinetic energy to bond materials. Powder particles are accelerated using an inert gas—typically helium or nitrogen—until they reach supersonic speeds. Upon impact, these particles plastically deform and expand their surface area by approximately 400%, exposing fresh, oxide-free surfaces. These newly exposed surfaces form strong metallurgical bonds without the need for melting, which preserves the structural and mechanical properties of both the coating and the substrate.

KM vs Traditional Thermal Spray

Because KM avoids high-temperature processing, it eliminates oxidation during deposition and reduces residual stress and heat-affected zones. This results in coatings with excellent ductility, density, and adherence—ideal for applications requiring wear resistance, corrosion protection, or electrical conductivity. KM is especially suitable for precision coatings on sensitive or thin substrates that would otherwise be damaged by thermal spray systems.

Patented Technologies Behind KM

Inovati holds multiple U.S. and international patents that enhance KM’s performance. One key patent covers the dual-phase, friction-compensated sonic nozzle design, capable of accelerating particles up to 1000 m/s using significantly less gas than other cold spray methods. Another patent protects the brush-sieve powder feeder, which allows precise and consistent delivery of a wide range of feedstock materials—from 500 nm to 50 µm—at flow rates between 1 and 100 grams per minute.

Applications and Unique Capabilities

Thanks to these innovations, KM is uniquely capable of depositing difficult materials such as heavy metals, WC-Co (tungsten carbide–cobalt), niobium, and MCrAlY alloys using impact consolidation. These capabilities position KM as a leading solution for high-performance coatings in aerospace, defense, and advanced manufacturing sectors. Whether used for corrosion resistance, structural repair, or wear protection, KM enables application-specific coatings with tunable hardness and excellent bond strength.