--- title: "RIT gets $3 million NSF grant to advance metal 3D printing with recycled feedstocks" url: https://www.voxelmatters.com/rit-gets-3-million-nsf-grant-to-advance-metal-3d-printing-with-recycled-feedstocks/ date: 2026-06-14 modified: 2026-06-14 lang: en author: "Joseph Caron-Dawe" description: "Rochester Institute of Technology has received a nearly $3 million grant from the National Science Foundation (NSF) to develop a new approach to metal additive manufacturing. The research centers on..." categories: - "AM Research" - "Metal Additive Manufacturing" - "Money & Funding" tags: - "future" image: https://www.voxelmatters.com/wp-content/uploads/2026/06/NMSU-grant-640x360.jpeg word_count: 350 --- # RIT gets $3 million NSF grant to advance metal 3D printing with recycled feedstocks [Rochester Institute of Technology](https://www.voxelmatters.com/rochester-institute-of-technology-installs-elemx-metal-3d-printer/) has received a nearly $3 million grant from the [National Science Foundation (NSF)](https://www.voxelmatters.com/unf-secures-nsf-grant-to-tackle-defects-in-laser-powder-bed-fusion/) to develop a new approach to metal additive manufacturing. The research centers on molten metal droplet jetting, a process in which millions of tiny molten metal droplets are deposited and fused during cooling to build a part layer by layer. While the technique exists in current systems, the team's version separates the melting and deposition stages — a distinction the researchers said could allow for faster production rates and the use of lower-cost materials, including recycled metals and machining scrap. The separation stands in contrast to conventional metal 3D printing, which typically requires specialized spherical metal powders that are expensive to procure and difficult to store. “Many traditional metal 3D printers require highly specialized, expensive and potentially hazardous spherical metal powders,” said Chaitanya Mahajan, Assistant Professor of Industrial Engineering at New Mexico State University (NMSU), who is serving as co-principal investigator. “These powders have a limited shelf life, absorb moisture, and present severe explosion and inhalation risks, making them incredibly difficult to transport and store in harsh environments.” ## Multi-nozzle design and defense applications [Beyond feedstock flexibility](https://www.voxelmatters.com/astm-develops-proposed-standard-for-metal-powder-feedstock/), the team is working to address throughput limitations common to single-nozzle droplet jetting systems, which are prone to clogging and slow build rates. The research incorporates multiple nozzles alongside advanced modeling techniques to increase production speed while maintaining part quality. Mahajan said the ability to convert scrap metal into functional components carries implications for both commercial manufacturers and defense supply chains, particularly in environments where sourcing materials is constrained. “For me, transforming aluminum scrap into high-precision parts redefines the limits of additive manufacturing,” Mahajan said. “This project demonstrates that the future of mass production lies in bridging the gap between circular sustainability and next-generation engineering.” The approach could also support the production of multi-material structures with embedded components. “The ability to create cost-effective 3D printed components will be essential when creating multi-material smart structures,” Mahajan said. “Allowing manufacturers to print embedded wiring and data components into structures, eliminating the weight and clutter of traditional external wiring harnesses.”