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Cold Gas Dynamic Manufacturing (CGDM) is a high-rate, direct deposition process capable of combining many dissimilar materials in the production of a single component. The process is based on Cold Gas Dynamic Spraying (CGDS) -a surface coating technology in which small, un-heated particles are accelerated to high velocities (typically above 500 m/s) in a supersonic gas jet and directed towards a substrate material. The process does not use a heat source (as with similar plasma and HVOF spray technologies), but rather employs the high kinetic energy of the particles to effect bonding through plastic deformation upon impact with the substrate or previously deposited layer. As a consequence it lends itself to the processing of temperature sensitive material systems such as oxidising, phase-sensitive or nano-structured materials. To achieve metallic bonding incident particles require velocities greater than a certain materialspecific threshold value, such that thin surface films are ruptured, generating a direct interface. This bonding mechanism has been compared to explosive welding. This paper discusses the further development of the CGDS technique from surface coating technology into the basis for a novel Additive Fabrication process. The description of the apparatus is presented in addition to the basic processing conditions for the deposition of aluminium material. Particular attention is paid to the morphology of the deposited material, the microstructure and the interfacial boundary between splats.

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