Friction Stir Additive Manufacturing Patents 2026
Friction Stir Additive Manufacturing Patents 2026
Solid-state FSAM is emerging as a credible alternative to fusion-based metal AM for high-strength aluminum and titanium structures. Active US patents from Blue Origin, Lockheed Martin, NASA, and the University of Alabama anchor the current IP landscape.
What Is Friction Stir Additive Manufacturing?
Friction Stir Additive Manufacturing (FSAM) is a family of solid-state, thermomechanical metal deposition processes that build metallic structures layer-by-layer without melting the feedstock. Operating entirely below the melting temperature of the workpiece, it fundamentally distinguishes itself from beam-based processes such as selective laser melting and electron beam melting.
Three principal sub-processes define the FSAM family: sheet-lamination FSAM (SL-FSAM), which uses sequential friction stir lap welding of metal sheets; Additive Friction Stir Deposition (AFSD), which forces a solid rod through a rotating hollow tool; and wire-based variants that enable continuous deposition and composite reinforcement distribution.
The defining mechanical advantages emphasized across retrieved records include elimination of solidification defects, equiaxed grain refinement, reduced residual stress, high-strength bonding of dissimilar alloys, and suitability for large-format structures with minimal post-processing distortion. These properties make FSAM particularly attractive for aerospace, defense, and structural repair applications.
The field evolved through three phases: a foundational FSW/FSP phase pre-2019, an emergence and definition phase from 2019–2022 when AFSD was formally defined as a forging counterpart of fusion-based AM, and a maturation phase from 2023–2026 characterized by targeted engineering patents from Blue Origin, NASA, IIT Kharagpur, IIT Guwahati, and the University of Pittsburgh.
FSAM Patent Activity by Phase and Technology Cluster
Among the 8 patents retrieved, 7 were published in 2023 or later, confirming that the most active filing period in this dataset is 2023–2026. The AFSD cluster shows the highest patent activity, while hybrid process integration is the fastest-emerging sub-cluster.
FSAM Patents by Technology Cluster (Retrieved Dataset)
AFSD rod-feedstock patents account for the largest cluster, followed by hybrid FSAM integration and wire-based/bobbin variants.
↗ Click bars to exploreFSAM Patent Filing Activity by Phase (2013–2026)
Filing activity accelerated sharply in the maturation phase (2023–2026), which produced 7 of the 8 retrieved patents.
↗ Click bars to exploreKey FSAM Application Sectors and Research Domains
FSAM has been adopted or targeted across four primary sectors — aerospace and space launch, defense and structural repair, metal matrix composites, and automotive/marine hybrid structures — with aerospace representing the dominant industrial adoption domain in this dataset.
Aerospace and Space Launch Structures
SL-FSAM was first deployed industrially by Airbus in 2006 and Boeing in 2012 for lightweight aluminum airframe components. Blue Origin holds two active US patents filed in 2025 targeting space launch vehicle structures with integrated internal passages such as actively cooled chambers and manifolds. Lockheed Martin’s 2021 active US patent on tension-wound solid-state AM was explicitly developed for large aluminum spaceflight structures as an alternative to fusion-based processes that produce inferior grain sizes.
Aerospace AMDefense and Structural Repair
AFSD’s ability to fill volume damage including through-holes and grooves in 7075 aluminum without hot cracking makes it a critical repair technology for defense assets, as demonstrated in 2019 literature on 7075 Al repair. The University of Alabama’s 2023 active US patent covers continuous large-deposit AFSD with non-circular feed rod anti-slip geometry. Wire-based FSAM, documented in 2022 literature, targets field-deployable structural repair with improved portability.
Defense RepairMetal Matrix Composites and Functional Structures
FSAM’s severe plastic deformation mechanism enables uniform dispersion of ceramic or metallic particles such as SiC and Al₂O₃ at volume fractions exceeding 30%, with refined interparticle spacing below 1 µm, as reported in 2022 literature on multifunctional MMCs. A 2022 study fabricated functionally graded structures from alternating AA6061-T6/AA7075-T6 layers using solid-state AM. These MMC capabilities are not yet heavily patented in the retrieved dataset, representing a potential IP filing opportunity.
Composites AMAutomotive and Marine Bimetallic Walls
Delhi Technological University’s 2026 pending IN patent demonstrates CMT-WAAM deposition followed by FSP post-treatment at the interface layer of bimetallic ER4043/ER5356 aluminum walls to improve wear resistance and grain refinement, with explicit applicability to automotive and marine sectors. IIT Kharagpur’s 2026 pending IN patent on wire-fed FSAM also targets large-scale metal product fabrication in these industries. These hybrid WAAM-FSP approaches address dissimilar aluminum alloy structures requiring enhanced tribological performance.
Hybrid AMLeading Assignees in FSAM Patent Filings
Among 8 retrieved patents, Blue Origin leads commercial filing activity with two US patents in 2025, while Lockheed Martin and NASA hold the foundational active US positions. India’s IIT ecosystem has filed three pending patents in the 2024–2026 window.
FSAM Patents by Assignee (Retrieved Dataset)
↗ Click bars to exploreBlue Origin Manufacturing, LLC
Blue Origin is the most active single commercial FSAM filer in this dataset, with two US patents filed in 2025. The first active patent covers deposition head geometry with semi-cylindrical portions and chamfered inner surfaces to control weld profile; the second pending patent discloses FSAM-formed structural parts with integrated internal passages for actively cooled aerospace components. Both patents are explicitly directed at space launch vehicle structures.
United StatesLockheed Martin Corporation
Lockheed Martin holds one active US patent filed in 2021 covering tension-wound solid-state additive manufacturing, explicitly developed for large aluminum spaceflight structures as an alternative to fusion-based processes that produce inferior grain sizes. This represents the earliest active commercial FSAM patent in the retrieved dataset. Lockheed’s filing anchors the foundational IP layer for aerospace solid-state AM alongside NASA and Blue Origin.
United StatesNew FSAM Technology Directions Signaled by 2024–2026 Patents
Patents filed between 2024 and 2026 in this dataset point to five emerging engineering directions: integrated cooling passage structures, dual-tool wire-based FSAM, hybrid WAAM-FSP for bimetallic walls, bobbin tool simultaneous plasticization, and multi-process hybrid manufacturing platforms.
Integrated Passage and Cooling Channel Structures
Blue Origin’s 2025 pending US patent on FSAM-formed parts with integrated passages points toward using solid-state deposition to fabricate actively cooled rocket engine or aerospace structural components, replacing brazed or diffusion-bonded tube assemblies. The patent discloses integration of FSAM deposition with post-machining and tube-groove integration. This represents a direct commercial application of FSAM to next-generation space propulsion hardware.
Wire-Based FSAM with Dual-Tool Consolidation
IIT Kharagpur’s 2026 pending IN patent introduces a dual-tool W-FSAM architecture in which a leading wire-deposition tool is followed by a secondary consolidation tool, enabling more uniform composite reinforcement distribution and interfacial machining during multi-layer builds. This is documented as the first dual-tool FSAM configuration in this dataset. The system also accommodates composite reinforcement particle deposition and interfacial machining between layers.
AFSD vs. Sheet-Lamination FSAM: Key Dimensions
Click any row to explore further.
| Dimension | Additive Friction Stir Deposition (AFSD) | Sheet-Lamination FSAM (SL-FSAM) |
|---|---|---|
| Feedstock Form | Solid rod or wire feedstock forced through hollow rotating tool | Sequential stacked metal sheets joined via friction stir lap welding |
| Industrial Adoption | Active US patents from University of Alabama (2023) and Blue Origin (2025); demonstrated repair of 7075 Al | First deployed industrially by Airbus (2006) and Boeing (2012) for aluminum airframe components |
| Patent Status (Dataset) | Highest patent activity cluster in this dataset; 3 AFSD-specific patents retrieved | 1 dedicated sheet-lamination patent retrieved (IIT Guwahati, 2025, IN pending) |
| Primary Materials | High-strength aluminum alloys including 7075; composite reinforcement deposition possible | High-strength 7xxx-series aluminum; airframe stringers, stiffeners, and skins |
| Key Microstructural Outcome | Fully dense, equiaxed-grain microstructures in the as-printed state without melting | Gap-free bonding via intermediate milling; 2022 literature investigates eliminating mandatory milling step |
| Repair Capability | Demonstrated for filling through-holes and grooves in 7075 Al without hot cracking (2019 literature) | Not cited as a repair process in this dataset; oriented toward new structure fabrication |
| Hybrid Integration | Combined with DED and subtractive machining in University of Pittsburgh 2025 WO patent | Combined with FSP post-treatment in Delhi Technological University 2026 IN patent (WAAM-FSP) |
Frequently Asked Questions: Friction Stir Additive Manufacturing
The three principal FSAM sub-processes are: Sheet-Lamination FSAM (SL-FSAM), which sequentially stacks and friction stir lap welds metal sheets with optional intermediate milling; Additive Friction Stir Deposition (AFSD), which forces a solid rod feedstock through a rotating hollow tool to deposit material without melting; and Wire-Based FSAM (W-FSAM), an emerging variant using wire feedstock for continuous deposition and composite reinforcement distribution.
Active US FSAM patents in this dataset are held by Blue Origin Manufacturing, LLC (deposition head design, 2025), Lockheed Martin Corporation (tension-wound solid-state AM, 2021), the Board of Trustees of the University of Alabama (friction-based AM systems, 2023), and NASA (bobbin friction stir weld AM system, 2024). Blue Origin also has a pending US patent on integrated-passage structures (2025).
FSAM operates entirely below the melting temperature of the workpiece using frictional heat and severe plastic deformation, eliminating solidification defects that are inherent to fusion-based processes such as selective laser melting and electron beam melting. This produces fully dense, equiaxed-grain microstructures, reduced residual stress, and high-strength bonding of dissimilar alloys without the hot cracking risks associated with melting high-strength aluminum alloys like 7075.
Aerospace and space launch is the dominant application sector, with Airbus first deploying SL-FSAM industrially in 2006 and Boeing in 2012. Blue Origin’s two 2025 patents target space launch vehicle structures with integrated cooling passages, and NASA’s 2024 patent reflects investment in space-grade solid-state AM. Defense structural repair, metal matrix composites with ceramic particle loading above 30%, and automotive/marine hybrid bimetallic structures are additional application domains documented in this dataset.
Five emerging directions are visible: (1) integrated passage and cooling channel structures for actively cooled aerospace components (Blue Origin, 2025); (2) wire-based FSAM with dual-tool consolidation enabling composite reinforcement (IIT Kharagpur, 2026); (3) hybrid WAAM-FSP for bimetallic aluminum walls with improved wear resistance (Delhi Technological University, 2026); (4) bobbin tool FSAM for simultaneous substrate and feedstock plasticization (NASA, 2024); and (5) multi-process hybrid platforms combining DED, FSAM, and subtractive machining (University of Pittsburgh, 2025).
Process control and closed-loop automation are identified as underpatented in this dataset despite being documented in 2022 literature on closed-loop temperature and force control of AFSD — no corresponding patent appears in the retrieved records. Metal matrix composites with particle loading above 30% are also not yet heavily patented. No EU, JP, or KR jurisdiction patents appear in this dataset, suggesting either geographic concentration in US and India or a gap in the retrieved sample.
Data and insights on this page are based on a limited patent and literature dataset and are for reference only. Figures may not represent the complete technology landscape.