Worcester Polytechnic Institute (WPI) is leading a new initiative called “Rubble to Rockets” that aims to produce components from scrap metal and mixed alloys through additive manufacturing. The project applies machine learning to identify unknown source materials and understand how they bond when melted and 3D printed. This approach could enable manufacturing in resource-limited environments, with the project scheduled for completion in November 2027.
WPI student researchers in advanced manufacturing lab (Image Credit: WPI)
Associate Professor Danielle Cote, the lead researcher, emphasized the importance of building high-quality components from unknown materials with new confidence. The team will utilize artificial intelligence technology developed by a WPI PhD student to predict material behavior at various compositions. This system will optimize and automate characterization processes to maintain durability and strength while accelerating manufacturing.
As part of the initiative, researchers will design a proof-of-concept sounding rocket to test the structural integrity of mixed metals. This practical application will help measure performance and reliability of components produced through the new manufacturing process. The testing phase represents a critical step in validating the technology.
The WPI team is collaborating with several partners including Solvus Global, Nightshade Corporation, Citrine Informatics, and Siemens. Nightshade Corporation will convert scrap into powder, while Citrine Informatics will focus on AI and machine learning aspects of the project. Aaron Birt, CEO of Solvus Global, noted that “The future of manufacturing is at the intersection of so many disciplines, including software, robotics, AI, materials science, and mechanical engineering.”
