Kinetic Metallization™ provides a low-temperature and low-pressure technique for dimensional restoration of magnesium and aluminum alloy components. Inovati has developed a unique Al-Trans® (aluminum-transition metal) powder that permits dimensional restoration repairs of Mg alloy gearboxes and transmissions as well as repairs of Al alloy castings and wrought materials.  Using a handheld KM Spray Gun an operator is able to fill complex-shaped cavities induced by wear or corrosion damage with Al-Trans® powder formulations for dimensional restoration of these defects. This presentation will describe the KM repair process developed and the tests completed to qualify these type free form fabrication repairs. A portable KM-Mobile Coating System with a handheld KM Spray Gun provides the basic tool for enabling these types of repairs.