Cold Spray Needs a CNC Brain
Cold spray has reached a critical threshold and is now being asked to perform repeatable, certifiable, high-value repair and additive manufacturing—especially in aerospace and defense [1,2].
The Control Gap Holding Cold Spray Back
Most commercial cold spray systems today are still controlled like process equipment:
- PLC-centric architectures
- Sequential logic driving valves, feeders, and safety interlocks
- Motion is treated as an external or loosely coupled subsystem
This works for basic deposition, but becomes a bottleneck when precision is required:
- Tight synchronization between nozzle motion and powder delivery [3]
- Multi-axis contour following on complex repair geometries [4]
- Inline metrology and adaptive deposition [5]
- CAM-generated toolpaths and repeatability across machines [6]
In short, the process is being asked to do CNC work without CNC coordination.
A Motion-Centric Cold Spray CNC Platform
A more scalable architecture places a high-precision motion controller—such as an ACS Motion Control SPiiPlus platform—at the center of the system.
In this model, the motion controller is the deterministic real-time orchestrator of the entire cold spray process (Figure 1):
- Multi-axis nozzle and part motion
- Powder feed synchronization [7]
- Gas pressure and temperature setpoints
- Optional laser assist (LACS) coordination [8]
- Inline sensing and data capture [5,9]
- Safety-aware process gating
The result is an accurate Cold Spray CNC, not just a spray system with motion attached.
Why ACS Motion Control Fits Cold Spray Exceptionally Well
ACS controllers are designed for demanding, multi-physics manufacturing systems, making them a natural fit for cold spray.
Key Advantages:
- Deterministic, Nanosecond-Level Synchronization – Powder flow, laser assist, and gas events are synchronized directly to motion trajectory execution [7,8].
- CNC + Process Control in One Engine – Motion, high-speed I/O, process triggers, and real-time logging all executed from a single real-time kernel.
- Native G-Code and CAM Integration – Supports complex repair toolpaths, multi-pass buildup, and micro-repair strategies [6].
- Inline Sensing Without Compromising Motion – Profilometers, plume cameras, particle velocity diagnostics, and acoustic sensors can provide real-time feedback [5,9].
- Scalable from R&D to Certified Production – Supports open experimentation, locked-down production, and full traceability [2].
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From “Spray Parameters” to “Digital Repair Strategies”
Instead of tuning gas pressure, temperature, or powder feed in isolation, engineers can now define digital repair strategies:
- Toolpath + standoff + velocity
- Material-on-demand at precise locations
- Layer-by-layer buildup with verification [6]
Cold spray becomes:
- More repeatable
- More portable
- More certifiable
Ultimately, this is how cold spray becomes trusted for safety-critical repair.
The Path Forward
Cold spray is ready for its CNC moment.
By adopting a motion-first architecture — with platforms like ACS Motion Control acting as the unified CNC controller — the industry can unlock:
- Higher repair precision
- Better material efficiency
- Faster qualification cycles
- Seamless integration with modern digital manufacturing workflows
Bigger gas heaters or higher pressures won’t define the next generation of cold spray machines.
They’ll be defined by how intelligently motion and process are synchronized.
And that starts with choosing the right CNC brain.
References
- Assadi, H., Kreye, H., Gärtner, F., & Klassen, T. (2016). Cold spraying – A materials perspective. Acta Materialia, 116, 382–407. https://doi.org/10.1016/j.actamat.2016.06.034
- Champagne, V. K. (Ed.). (2016). The Cold Spray Materials Deposition Process. Springer. https://link.springer.com/book/10.1007/978-3-319-16772-5
- Yin, S., et al. (2018). Cold spray additive manufacturing and repair: Fundamentals and applications. Additive Manufacturing, 21, 628–650. https://doi.org/10.1016/j.addma.2018.04.017
- Meyer, M. C., et al. (2018). In-situ diagnostics and control in cold spray processes. Surface & Coatings Technology, 350, 1073–1082. https://doi.org/10.1016/j.surfcoat.2018.07.033
- Fauchais, P., Montavon, G., Bertrand, G., & Pawlowski, L. (2014). From powders to thermally sprayed coatings. Journal of Thermal Spray Technology, 23, 337–360. https://doi.org/10.1007/s11666-014-0064-0
- Gibson, I., Rosen, D., & Stucker, B. (2021). Additive Manufacturing Technologies (3rd ed.). Springer. https://link.springer.com/book/10.1007/978-3-030-56127-7
- ACS Motion Control. SPiiPlus Motion Controller Technical Manual. Accessed 2026. https://www.acsmotioncontrol.com
- ACS Moti