SolidStir Technology: A Multifunctional Solid-State Manufacturing Platform for Additive Manufacturing, Repair, Extrusion, and Recycling

SolidStir® technology is a multifunctional, solid-state manufacturing platform that combines extrusion, additive manufacturing (AM), structural repair, and recycling in a single system. By using frictional heat and severe plastic deformation to create metallurgical bonding without melting, it avoids many of the limitations of conventional fusion-based manufacturing, including porosity, solidification cracking, residual stresses, and undesirable cast microstructures. Compared with fusion-based and existing solid-state AM processes, SolidStir® produces fully dense, defect-free deposits with strong interlayer bonding and a dynamically recrystallized fine-grained microstructure that delivers wrought-like mechanical properties. The process also offers control over second-phase particle fragmentation, reduced residual stress, and control on deposit resolution. In addition, it is feedstock-form agnostic and can be integrated into existing CNC milling platforms. Across a wide range of applications, SolidStir® has demonstrated the ability to produce fine-grained, defect-free deposits with mechanical performance exceeding that of the base material. Its use of conventional CNC systems and low-cost feedstocks, including extruded rods, recycled metals, and off-spec materials, lowers both manufacturing cost and the barrier to adoption while improving sustainability. Its localized deposition capability also makes it well suited for structural repair of high-value components in aerospace, defense, and transportation. Collectively, these capabilities position SolidStir® as a scalable, sustainable, agile and transforming solution for next-generation manufacturing.