FormAlloy Technologies

HardwareSpring Valley, USAFounded 2016· One of 1725 Hardware companies tracked by AMPulse

A manufacturer of advanced Directed Energy Deposition (DED) systems and software for high-precision metal 3D printing, component repair, and cladding.

CEO / Founder: Melanie Lang
Team Size: 11-50
Stage: Active
Total Funding: $10.76M
Latest Round: Grant
Key Investors: America Makes, NASA, Creative Destruction Lab

Technology & Products

Key Products

X-Series and L-Series Directed Energy Deposition (DED) systems, DEDSmart® software, Alloy Development Feeder (ADF).

Technological Advantage

Offers a unique hybrid capability to switch between powder and wire feedstocks in a single system, providing the precision of powder with the high deposition rates and cost-efficiency of wire.

Differentiation

Value Proposition

Delivers high-speed metal deposition with superior material properties and real-time closed-loop control, enabling the production of complex, multi-alloy components with reduced defects and waste.

How They Differentiate

Proprietary DEDSmart® software for real-time closed-loop control and the Alloy Development Feeder (ADF) capable of mixing up to 16 different powders for functionally graded materials.

Market & Competition

Target Customers

Tier 1 aerospace suppliers, defense contractors, energy companies, and heavy industrial manufacturers requiring large-scale or multi-material metal parts.

Industry Verticals

Aerospace & Space Exploration, Defense, Energy (Oil & Gas, Nuclear), Automotive, Tooling & Mining

Competitors

RPM Innovations, Hybrid Manufacturing Technologies, 3D Hybrid Solutions

Growth & Milestones

Growth Metrics

Expanded operations in 2024 with a new Application Development Center in San Diego; estimated ARR between $1M - $1.5M.

Major Milestones

Winner of the America Makes PADAM Project in 2024, Opened new Application Development Center in San Diego in 2024, CEO Melanie Lang named 2023 SWE Entrepreneur of the Year, Successful integration of high-power blue laser technology with NUBURU in 2022

Notable Customers

Defense and industrial customers, aerospace industry, NASA.

https://www.formalloy.com

Official records

Filings, certifications, and programme counts AMPulse can show for this company.

[F] SBIR/STTR · 3 AM awards · latest 2020

[F] Open Call for Innovative Defense-Related Dual-Purpose Technologies/Solutions with a Clear Air Force Stakeholder Need · 2020 · USD 41,815
[F] Data-Driven Modeling of Directed Energy Deposition (DED) for Defect-Free Builds using Real-Time Monitoring Approaches · 2020 · USD 124,987
[F] Metal Additive Manufacturing to Build and Repair High-Value Copper Components · 2020 · USD 997,849

Equipment deals on record

Publicly disclosed purchases or installs only.

IRA FUNDED DUAL WIRE AND POWDER FED DIRECTED ENERGY DEPOSITION ADDITIVE MANUFACTURING MACHINE2024-07-01Buyer: Department of Energy · Supplier: FORMALLOY TECHNOLOGIES, INC

View full equipment ledger

Why this company matters

AMPulse analysis, not a company disclosure

FormAlloy Technologies produces Directed Energy Deposition (DED) systems and software for high-precision metal additive manufacturing, component repair, and cladding. Founded in 2016 and based in Spring Valley, USA, the company targets applications where speed, material flexibility, and defect reduction are critical. Its systems compete with those from RPM Innovations, Hybrid Manufacturing Technologies, and 3D Hybrid Solutions.

The core differentiator is the proprietary DEDSmart software, which provides real-time autonomous process adjustments during deposition. The Alloy Development Feeder (ADF) enables printing of functionally graded materials by mixing up to 16 different alloys on the fly. FormAlloy's X-Series and L-Series DED systems also offer a hybrid capability to switch between powder and wire feedstocks in a single build, combining powder precision with wire's higher deposition rates and lower cost.

Customers include tier 1 aerospace suppliers, defense contractors, energy companies, and heavy industrial manufacturers. Notable partners include NASA, the U.S. Navy, and the Department of Defense. FormAlloy won the America Makes PADAM project in 2024 and has integrated high-power blue laser technology from NUBURU. The company opened a new Application Development Center in San Diego in 2024 and reports estimated ARR between $1 million and $1.5 million.

FormAlloy's strategic moat lies in its closed-loop control software and multi-alloy feeder, which are difficult to replicate. However, DED remains a niche segment within metal AM, and scaling adoption beyond aerospace and defense will require broader industry acceptance of functionally graded materials and repair workflows.