Cold Spray Additive Repair Patents: Who Leads, Where the Gaps Are 2026
- 77.4% concentration. The top 5 assignees hold 48 of all 62 records in scope — this is a field where a handful of aerospace and defence filers set the terms.
- Filings peaked in 2020 at 9. and the trend has flattened since (2022 sits at 6), suggesting the core claim space around bonding and critical velocity is largely staked out.
- C23C coating claims dominate. at 61.3% of records, while turbine-specific application (F01D, 11.3%) and metal working integration (B23P, 12.9%) remain comparatively thin.
Filing growth compares 2021 (4 records) with 2024 (5) — a three-year span. 2024 is the most recent year we treat as complete: publication lags filing by roughly 18 months, so 2025 onwards are still filling in and any growth rate that ends there would understate the field. Top-5 share is the combined record count of the five largest assignees divided by all 62 records in scope (CR5), not by the ranked leaders only.
What this landscape covers
Cold spray additive repair uses supersonic particle deposition to rebuild worn or damaged metal components without the heat input of welding or thermal spray, which matters for parts where melting would compromise the base material’s properties. The claim space tracked here spans bonding mechanisms, critical velocity thresholds, substrate pair compatibility, deposition efficiency, and the qualification processes that let a repaired part return to service. This is a repair and restoration technology first, additive manufacturing second — the search scope centres on components already in the field, not net-shape builds from scratch.
The 62 records in scope run from 2015 through the 2026 cut-off, concentrated in aerospace structural and turbine repair. Publication lags filing by roughly 18 months, so the most recent one or two years in any trend understate real filing activity.
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Filing trend and technology composition
Two views of the same 62 records: how filing activity has moved year over year, and which IPC subclasses carry the claims.
Filing trend: a 2020 peak, then flattening
Filings rose from 2 in 2017 to a peak of 9 in 2020, then eased to 6 by the 2022 midpoint — a pattern consistent with a technology whose core mechanisms are claimed and whose filers are now defending or extending rather than staking new ground.
IPC technology mix: coating claims dominate
C23C (coating and surface deposition) appears in 61.3% of the 62 records, well ahead of B33Y additive manufacturing (33.9%) and B64F aircraft ground installations (29.0%). Because a record can carry several IPC classes, these shares add to more than 100% of the record total — that is expected and reflects how often cold spray repair claims cross coating, powder metallurgy, and aerospace-specific application together.
Shares are the percentage of the 62 records in scope. A patent can carry several IPC classes, so the shares add up to more than 100%.
Go deeper on Cold Spray Additive Repair of Components with Eureka
This page is one run against one query. Ask Eureka your own question about cold spray additive repair of components and every answer comes back with the patent numbers behind it.
Try EurekaThe most-cited records in this dataset
Systems and methods for cold spray additive manufacturing and repair with gas recovery
Implementations provide cold spray additive manufacturing ("CSAM") with gas recovery in situ in an open environment without requiring part disassembly and removal to a repair facility. Recapturing and reusing gas reduces costs and avoids risk of new damage to parts from contemporary pre-existing CSAM processes. A gas recovery nozzle attaches to a supersonic nozzle and sends used gas to a gas recovery sub-system by capturing gas deflected on impact with the part, storing it for reuse.Filed by The Boeing Company, published 2020-12-31 as US20200407855A1.
| # | Publication no. | Patent title | Citations |
|---|---|---|---|
| 1 | US20140115854A1 | Methods for cold spray repair | 27 |
| 2 | US20190009300A1 | Method for repairing turbine component by application of thick cold spray coating | 22 |
| 3 | US20150063903A1 | Methods for treating aircraft structures | 20 |
| 4 | WO2013142902A2 | Methods for treating aircraft structures | 19 |
| 5 | US20170333934A1 | Masking plug for cold spray repair at counterbore hole | 11 |
| 6 | US10099322B2 | Methods for cold spray repair | 10 |
| 7 | US20160340060A1 | Methods for restoring an aircraft frame element | 8 |
| 8 | CA2772838A1 | Methods for treating aircraft structures | 8 |
| 9 | US20240213834A1 | Permanent Magnets with Integrated Phase Change Materials | 6 |
| 10 | US10315218B2 | Method for repairing turbine component by application of thick cold spray coating | 6 |
Citation counts inside a searched corpus favour older records — treat them as a signal of influence on the field, not of current commercial importance.
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Three read-throughs from the concentration, citation, and technology-mix data.
Field access runs through a small group
The top 5 assignees combine for 48 of the 62 records in scope. A field this concentrated means freedom-to-operate work should start with those portfolios' claim scope on bonding and critical-velocity thresholds, not with a broad novelty search across all 18 ranked filers.
Core mechanism claims are largely staked
Filing activity rose to a 2020 peak and has since leveled off rather than accelerated. Combined with several leading assignees showing no filings in the latest tracked year, this points to a technology where the foundational bonding and deposition-efficiency claims are already written, and new entrants face denser prior art than the raw record count suggests.
Early aircraft-repair filings anchor the field
The most-cited records date to the mid-2010s and centre on aircraft structure repair and thick cold spray coatings for turbine components. New filers should expect examiners to cite these as baseline art for any claim touching masking, substrate treatment, or thickness control.
Eureka can read the same corpus for gaps instead of for coverage: under-claimed branches adjacent to cold spray additive repair of components, with the prior art for and against each one.
Who holds the claims, and where they are not filing
The ranked leaders sit almost entirely in aerospace and defence, with national research bodies and materials specialists filling out the tail.
A single filer well ahead of the field
The leading assignee holds 24 of the 62 records in scope, more than four times the fifth-place count of 4. That gap is unusually wide for this dataset size and signals a filer treating cold spray repair as a defended core capability rather than an opportunistic filing area.
A tight cluster behind the leader
Places two through five cluster closely together before the count drops off, forming the group whose combined 48 records make up the 77.4% top-5 share. This is the group most likely to have overlapping claims on substrate pairs and qualification procedures.
A wide but shallow tail of entrants
Beyond the top 10 — which together hold 95.2% of all 62 records — remaining assignees appear with a single filing each. National research councils and university-affiliated boards sit in this tail, often around niche substrate combinations rather than core aerospace repair.
| Assignee | Recent year | YoY |
|---|---|---|
| The Boeing Company | 0 | -100% |
| ROSEBANK ENG | 0 | — |
| General Electric Company | 0 | — |
| Sikorsky Aircraft Corporation | 0 | — |
| National Research Council of Canada | 0 | — |
| RUAG AUSTRALIA PTY LTD | 0 | — |
| Baoshan Iron & Steel Co., Ltd. | 0 | — |
| WIDENER CHRISTIAN | 0 | — |
Where to take this analysis
The dataset points to a concentrated but not closed field. These are the next steps worth running before committing R&D or filing budget.
Run freedom-to-operate on the top 5
With 77.4% of records held by five assignees, a targeted FTO review of their claim scope on bonding, critical velocity and substrate pairs will tell you more than a broad novelty search.
Explore assignee portfolios in EurekaScreen the under-claimed branches
Turbine tip restoration, in-field gas recovery and repair-grade powder cost sit below the core coating and aircraft classes in filing density — worth a closer look before assuming the space is closed.
Screen white space in EurekaTrack qualification-related filings specifically
Qualification and restoration language recurs across the search scope; watching new filings that combine these terms with turbine or structural substrates will surface emerging claim activity earlier than annual trend data.
Set up monitoring in EurekaCommon questions on cold spray repair patents
The dataset ranks 18 assignees, and the leading one holds 24 of the 62 records in scope, well ahead of the fifth-place holder at 4. This is a highly concentrated field: the top 5 assignees combined account for 77.4% of all records. Anyone assessing freedom to operate should focus first on the leading filer's claim scope rather than treating the field as evenly distributed across many small players.
Filing activity peaked in 2020 at 9 records and had eased to 6 by the 2022 midpoint, with several leading assignees showing no filings in the most recent tracked year. Because publication lags filing by roughly 18 months, the last one or two years in any dataset understate true activity, but the broader trend through the midpoint already points to a flattening rather than continued growth. That suggests the core bonding and deposition mechanisms are largely claimed, with remaining activity concentrated in defensive or incremental filings.
Coating and surface deposition (IPC class C23C) appears in 61.3% of the 62 records, making it the dominant technology axis, followed by additive manufacturing methods (B33Y, 33.9%) and aircraft ground installation applications (B64F, 29.0%). Powder metallurgy, general coating processes, spraying equipment, metal working integration and turbine-specific application each appear in smaller but still meaningful shares. Because records often carry multiple IPC classes, these percentages overlap rather than sum to 100%.
US20200407855A1, filed by The Boeing Company and published in December 2020, covers cold spray additive manufacturing with in-situ gas recovery — capturing and reusing deflected supersonic gas during repair without disassembling the part. It specifically addresses reducing gas cost and avoiding new damage during open-environment repair. Anyone building a competing in-field repair system that recaptures and reuses process gas during cold spray should review this filing's specific mechanical coupling and nozzle claims before designing a similar recovery path.
Relative to the dominant coating and aerospace-structure claims, filing density is thinner around turbine blade tip restoration specifically, non-aerospace substrate pair qualification, and powder cost reduction for repair-grade feedstock. These are not unclaimed, but they sit well below the 61.3% density seen in core coating claims, making them worth a focused prior-art screen before committing to a filing strategy. The long tail beyond the top 10 assignees also shows single-filing entrants working niche substrate combinations, which can indicate either early-stage opportunity or narrow, already-settled niches.
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Disclaimer. This page is generated from Patsnap Eureka data drawn from a limited snapshot of global patent and scientific-literature records, and is provided for general information and reference only.
Patent data carries inherent limitations: recent filings (typically the most recent 18–24 months) are under-counted due to standard publication lag; counts may be reported at either a patent-family or a patent-record basis and are not always directly comparable; classification, applicant-name, and citation data may contain errors, duplicates, or omissions; and the underlying search query defines and constrains the scope shown. As a result, the analysis may be incomplete or inaccurate and may not reflect the full technology landscape.
Nothing on this page constitutes an exhaustive prior-art, novelty, freedom-to-operate, or validity search, nor does it constitute legal, financial, investment, or professional advice, and it should not be relied upon as such. Any patent, commercial, or strategic decision should be verified independently and reviewed with qualified patent, legal, and domain professionals. Patsnap makes no warranties, express or implied, as to the accuracy, completeness, or fitness for any particular purpose of the information presented.
Machine translation. Assignee and organisation names originally recorded in Chinese, Japanese or Korean have been rendered into English by an AI translation step so that the tables stay readable. These renderings are best-effort and may not match a company’s registered English name; the original name is what the underlying patent record carries, and it is what any Eureka query launched from this page uses.