Worcester Polytechnic Institute (WPI) has been awarded $6.3 million for a groundbreaking initiative that could transform additive manufacturing by enabling the rapid production of high-quality components from scrap metal.

Funded by the Defense Advanced Research Projects Agency (DARPA), this innovative approach aims to ensure that essential components can be produced even in the most resource-limited environments, including where access to traditional supply chains is limited, such as battlefields or remote search-and-rescue locations.

Labeled “Rubble to Rockets,” the initiative applies a machine learning approach to identify materials such as scrap metal and mixed alloys to understand how they react and bond together before being melted, mixed, and 3D-printed to form new parts that are strong and reliable. This would eliminate repeated testing and adjusting operations that traditional 3D printing requires. 

According to Danielle Cote, Associate Professor, Harold L. Jurist ’61 and Heather E. Jurist Dean’s Professor of Mechanical and Materials Engineering and lead researcher on the project, “This work is crucial as it allows us to build high-quality components from unknown source materials with new confidence. By improving our predictions and understanding of material performance, we can pave the way for new advancements in additive manufacturing from diverse and unpredictable sources.”

The team uses artificial intelligence (AI) technology developed by Citrine Informatics to predict material behavior at various compositions, optimizing and automating the characterization processes. By streamlining the procedure, the product can be manufactured at a rapid pace but not at the expense of durability and strength. Researchers plan to design a proof-of-concept sounding rocket to test the structural integrity of mixed metals and measure performance and reliability.

Wider Applications and Future Impact

Beyond defense applications, this work has broad applications and could be deployed in submarines, aircraft carriers, disaster relief zones, and remote locations where traditional supply chains are difficult to maintain.

By addressing key risks, including material performance, equipment size, and predictive model accuracy, the innovation is paving the way for more resilient and sustainable manufacturing solutions that support both emergency response and long-term infrastructure needs.

The WPI team will work with subcontractors including two WPI-alumni led companies, Solvus Global and Valis Insights, as well as Siemens and Nightshade Corporation which will perform scrap conversion into powder. By integrating advanced material informatics, AI-driven decision-making, and innovative additive manufacturing technologies, the initiative is helping to train the next generation of engineers and scientists, ensuring a skilled workforce that can sustain and expand these innovations into the future.

In addition to Cote, WPI assistant research professor Kyle Tsaknopoulos will work on the project with several PhD, master’s, and undergraduate students. The project is expected to be completed in November 2027.

For information: 

Worcester Polytechnic Institute

Citrine Informatics 

Sounding Rocket Explanation

Slovus Global 

Valis Insights

Images courtesy of WPI.