Last week, we explored how the Defense Advanced Research Projects Agency (DARPA) is pushing the boundaries of additive manufacturing, and the momentum is not slowing down. On June 4th, the Worcester Polytechnic Institute (WPI) announced a $6.3 million grant from DARPA to develop a framework for turning scrap metal into 3D-printable material. The goal of the project, titled “Rubble to Rockets,” is to make it possible to produce critical components anywhere, even in resource-scarce environments like battlefields and search-and-rescue operations.
One key factor of “Rubble to Rockets” will be the use of machine learning. The WPI team will use artificial intelligence to identify materials like scrap metal and mixed alloys to understand how they react and bond together before being melted and mixed. 3D printing requires a precise understanding of materials, and typically, the process demands carefully controlled materials and repeated testing. However, that is not always possible when on the field or in an urgent situation.
VALIS team member evaluating metal (Credit: VALIS)
The researchers will use AI developed by a WPI PhD student to predict how a material will behave given various compositions. This will streamline the process for characterizing materials, allowing for faster production but without sacrificing durability or strength.
“This work is crucial, as it allows us to build high-quality components from unknown source materials with new confidence,” said Associate Professor Danielle Cote, Professor of Mechanical and Materials Engineering, and the lead researcher on the project. “Our goal is not just to build a single solution, but to create a framework that guides future innovations. 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.”
From Rubble to Rockets… And Beyond
To test their framework, the WPI team will design a proof-of-concept sounding rocket to evaluate the structural integrity of mixed metals. However, the potential applications extend far beyond this initial test. Industries such as energy and transportation could use the technology in a wide range of environments, including submarines, aircraft carriers and disaster relief zones, where reliable materials are critical but traditional supply chains are hard to maintain. The WPI framework aims to provide a sustainable solution by addressing key challenges: material performance, equipment size and the accuracy of predictive models. This approach supports both emergency response needs and long-term manufacturing demands.
In addition to Cote, assistant research professor Kyle Tsaknopoulos will work on the project with several PhD, master’s, and undergraduate students. The WPI team is also collaborating with several subcontractors to complete the project, including two WPI-led companies, Siemens, and two businesses from California. One of the Californian businesses, the Nightshade Corporation, will convert scrap into powder. The other business, Citrine Informatics, will focus on AI and machine learning. VALIS, one of the WPI-led companies, will also work on the recycling.
Scrap metal being melted along with in-melt analysis (Photo credit: VALIS)
“VALIS was founded on the mission of delivering enabling technology to maximize the recovery of valuable materials for future generations,” said Emily Molstad, co-founder and CEO of VALIS Insights, a grant subcontractor. “We see the recycling industry becoming increasingly vertically integrated as raw material producers and manufacturers aim to secure a reliable supply of scrap material and increase recycled content to drive down costs. The technology being developed through this program will unlock new levels of upcycling capabilities not only in remote, resource-restricted locations, but across the recycling value chain with the potential to strengthen domestic manufacturing capabilities.”
The project is expected to be completed in November 2027, so until then, we will be on the lookout for updates.
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*Cover Photo: WPI student researchers in the advanced manufacturing lab. Credits: WPI