Additive Manufacturing
Metallic Components Meeting
Form, Fit, and Function.

Produce parts with well-understood mechanical performance in a design space that goes beyond conventional manufacturing.

example parts

FAST FACTORY
Design, Machining,
& Assembly

Design, Manufacture, Finish, Testing, and Assembly all under one roof.



Capabilities Inquiry

Integrated Computational
Adaptive Additive Manufacturing iCAAM

Model-Based Qualification for Additively Manufactured Parts

Performance Prediction

In-Situ
Additive Manufacturing Process Monitoring

Process monitoring allows for high fidelity non-destructive evaluation during the
melting process for performance predictions and part qualification.

Co-Axial with Laser Wearables

High-Throughput
Microstructure Characterization
and Mechanical Testing

MRL has developed novel solutions to increase microstructure collection and analysis as well as fatigue testing by orders of magnitude compared to conventional methods.

Microstructure Characterization Mechanical Testing

R&D to Optimize
Metallic Alloys
Processing and Post-Processing

Determining the optimal processing and post-processing for current and new alloys

Process Post-Process Novel Alloys

Be Original.

Physical Capabilities

MRL is a Fast Factory. We have what you need for rapid low volume production and prototyping in house.

Manufacturing

Manufacturing

Form, Fit, and Function.
MRL's model-optimized additive manufacturing methodology can produce high-quality parts from a wide range of metallic materials including Al, Ti, Fe, Ni, Mg, CoCr, and high entropy alloys using Electron or Laser Powder Bed Fusion or Wire Arc Additive Manufacturing.

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Machining

Machining

One-stop Precision Machine Shop.
MRL can support all of your CNC, wire EDM, sawing, grinding, turning, and surface finishing needs to produce everything from small samples to finished components.

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Material Characterization

Material Characterization

Full microstructure characterization.
We are equipped to measure and analyze your microstructure using optical light microscopy or SEM/EBSD.

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Mechanical Testing

Mechanical Testing

Coupon and component testing.
MRL’s high-throughput multi-sample tension and fatigue test capability gets you results faster, at lower cost, without sacrificing quality. MRL can also perform static, quasi-static, cyclic, and dynamic tests on conventional sample geometries -- or design and fabricate custom test fixtures for sub- or component testing.

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Surface Finishing

Surface Finishing

Controlled Surface Finish.
Surface roughness has a large impact on a material's fatigue performance, corrosion pitting potential, and inspectability. Using MRL's trade-secret electro-chemo-mechanical polishing process, we can create a smooth, mirror-like finish on anything from samples to complex components.

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Nondestructive Evaluation

Nondestructive Evaluation

Material State Awareness.
MRL's long history and expertise with materials processing, microstructure characterization, crystallographic anisotropy, and data-science gives us a huge advantage in the interpretation of in-situ and ex-situ NDE data. Using Microstructure-informed NDE, we can help you obtain more information than you ever thought possible without ever cutting your part.

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Material Characterization

Material Characterization

Micro, Meso, and Macro.
Whether you already know what you're looking for or are just beginning to explore the impact of microstructure on the quality of your products, MRL can assist you in all aspects of quantitative metallography and texture analysis including design of experiments, sample preparation, data collection, interpretation, statistical analysis, and reporting.

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Forensic Metallurgy

Forensic Metallurgy

Sometimes things break.
There's a plethora of information present on any given fracture surface -- it helps to have MRL's expertise in materials, manufacturing, characterization, and fatigue and fracture expertise to extract it and use it to identify the root cause and make corrective actions.

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Modeling and Simulation

Modeling and Simulation

Design. Analyze. Optimize.
Whether you need continuum finite element simulations or want to explore micromechanical effects using fully coupled crystal plasticity, MRL's Modeling & Simulation eam can help you through all aspects of a product's life cycle including development, design optimization, manufacturing (forging, heat treatment), and failure analysis.

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Performance Prediction

Performance Prediction

From monotonic to cyclic.
MRL is committed to model-based, sensor-assisted qualification of low-volume production parts so we've developed a suite of physics-based performance-prediction tools to predict many design-relevant factors including strength and fatigue. Through transfer of learning we can quickly adapt these models to solve your most challenging problems.

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6

Awarded Patents

31

DoD R&D Contracts

30,000

Sq-Ft Facility

10,000,000

Dollars Won

Modeling & Simulation

MRL is the team behind the first cloud-based ICME software for qualification of additive manufactured parts.

Software Development

iCAAM is the world's first AM-focused digital twin. This software guides the designer to what is possible and considers the designer's needs up front. This software combines a world-class database infrastructure with novel ICME modeling, and model-based part qualification.

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Machine Learning

MRL has a long history with using machine learning to speed up and improve the accuracy of its modeling and predictions. AM produces a plethora of data and the only way to make sense of the data is to utilize the most recent advances in ML.

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Data Analytics

Data Analytics is where MRL got its start. Our expertise is in reducing data without misrepresentation. To do this, many industry-standard single-point metrics become higher order statistical representations for informed model input.

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Databases

Highly customizable dynamic combinations of SQL and document-based databases allow MRL to rapidly mine the raw data, metadata, and data products in our research. This facilitates MRL to infer relationships between process and part performance unlike any other company.

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ICME

Integrated Computational Materials Engineering is a nascent field that holds the future of advanced manufacturing. In order to get the most out of these new processing such as AM, an ICME approach is paramount to the success and extension of our design tools, specifically, iCAAM.

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Topology Optimization

MRL's patented approach to producing designs that are optimized for mass-to-performance allows designers to rapidly produce designs that will be manufacturable without the inclusion of additional support structures. It is also capable of handling multiple different load objectives (force, flow, heat).

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Be Original


The manufacturing world is rapidly changing. We are working to put the ability of complex manufacturing into to the hands of the masses. The industrial revolution (of the 18th century) brought about the factory and marked the end to an era that was predominated by artisan manufacturers. Since then, the global manufacturing process has followed a rigid strategy of prototyping followed by mass manufacture typically outside the US. Then, a substantial up-charge is added to the cost because the part needs to be transported and distributed. This manufacturing model is limited and MRL is working to give the freedom of manufacturing back to any person.

Right now, we are living in the era of transition to distributed manufacturing.

Distributed manufacturing means a transition from mass production to meso or micro production. The first demonstration of this transition is the proliferation of plastic printers now used by millions, just in the US. Plastic printing has allowed for the production of hundreds of thousands of unique designs and unique implementations but plastic, as a material, is limited in its application. MRL seeks the to surpass the impact that plastic printing has made on ingenuity by giving its customers access to metal 3D printing.

Over the last 10 years, MRL has worked tirelessly on over 30 combined projects with the DoD and DoE to demonstrate the ability of additively manufactured metal parts to perform at the same level as their conventional counterparts and in some cases to exceed the conventional performance. While completing these projects, MRL has been working towards its vision as a company. To combine our know-how and problem solving skills into a robust framework that has become the software iCAAM (Integrated Computational Adaptive Additive Manufacturing). Producing metal additively is not an easy process, but our software makes it easy. It combines thousands of hours of simulation and experiments into a software that leverages physics-based modeling, data-driven modeling, and machine learning to determine the optimal method of manufacture for optimal performance. Then, using the data from your builds, it is able to predict your part's location-specific performance so that you can be sure your part will meet your desired implementation.

Parent Company of

About Us


Materials Resources, LLC (MRL) is the leader in determining the impact that the micro and meso-scale characteristics of materials have upon the macro scale performance by using an advanced approach that Integrates the latest advances in Computational science, the principles of Materials science, for Engineering solutions (ICME). Our focus is on metallic additively manufactured material. We have been working with the DoD and DoE on over 30 contracts related to improving additive manufacturing processes and we have used the combined learning of these projects into the world’s first cloud-based ICME framework for producing the digital twin for your parts. Our goal as a company is to solve problems in the additive industry and produce solutions that allow any designer to build high quality parts with model-based qualification to support the use of the parts.

Our business was founded in 2009 by Ayman Salem Ph.D. after working at the Air Force Research Labs at Wright Patterson Air Force Base. At this point in time, the company’s focus was on using the ICME approach for characterizing the microstructure in conventionally wrought and cast Titanium especially obtaining high order statistical representations of microstructure for predicting material performance. We recognized a potential shift in the metal producing industry with the nascent metallic 3D printing industry and the company purchased its first metallic 3D printer. Using some of the tools we developed for conventional material microstructural characterization, and many new physics-based models, machine learning techniques, and a brand new database infrastructure, MRL has transitioned its focus to additive.


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