SPEE3D Cold Spray Metal Additive Manufacturing

SPEE3D is an Australian metal additive manufacturing company founded in 2014 by Byron Kennedy and Steven Camilleri, headquartered in Melbourne with research and development in Darwin and offices in the USA and the UK. It was created to solve the difficulty of sourcing metal parts caused by supply chain issues and part obsolescence, by producing cast-equivalent parts on site in hours or days rather than weeks or months.

Its Cold Spray Additive Manufacturing (CSAM) process uses a patented Phaser rocket nozzle that accelerates air to three to four times the speed of sound, so metal powder particles bond through kinetic energy instead of melting, without dangerous gases or complex infrastructure. TwinSPEE3D software automates tool paths directly from STL and STEP files. The range includes LightSPEE3D for parts up to about 5 kg, WarpSPEE3D and the containerised XSPEE3D for parts up to 40 kg at up to 100 g per minute, and the Expeditionary Manufacturing Unit for printing, post-processing and testing in the field. Customers include defence forces, OEMs, heavy industry, maritime operators, mining, universities and service bureaus.

• Cold spray process: metal powder is bonded by kinetic energy at supersonic speed instead of being melted.
• Phaser nozzle: a patented rocket nozzle accelerates air to three to four times the speed of sound.
• TwinSPEE3D software: tool paths are generated automatically from STL and STEP CAD files.
• Scalable printers: LightSPEE3D, WarpSPEE3D and XSPEE3D cover parts from about 5 kg up to 40 kg.
• Expeditionary unit: a containerised system prints, post-processes and tests metal parts in the field.
• Material portfolio: aluminium, aluminium bronze, stainless steel and copper powders with materials in development.

Vietnamese mining and cement companies can print worn pump housings, brackets and handles on site to shorten downtime. Shipyards and port operators can produce corrosion-resistant aluminium bronze or copper parts for vessels and cranes. Technical universities and research institutes can use cold spray systems to research non-weldable alloys and repair techniques for industry.

Large near-net-shape metal parts are deposited at up to 100 g per minute, so critical replacement parts can be produced in hours instead of waiting weeks or months for castings. Because the process does not melt metal, it needs no dangerous gases, complex infrastructure or extensive training. The containerised XSPEE3D and the Expeditionary Manufacturing Unit can be moved to remote sites, letting operators keep equipment running where the parts are needed.

Defence, mining and maritime operators increasingly want to produce metal spare parts at or near the point of need to reduce dependence on long supply chains and obsolete castings. In Southeast Asia, mining sites, ports, shipyards and heavy industry plants often wait weeks for imported metal components, which creates demand for fast, deployable metal printing that does not require a full powder-bed facility.

Founded in 2014 by Byron Kennedy and Steven Camilleri, who previously built and sold In Motion Technologies to Regal Beloit. Headquartered in Melbourne, Australia, with R&D in Darwin and offices in Durham (New Hampshire, USA) and London. Partner of America Makes and member of the Additive Manufacturer Green Trade Association. Appointed Bryan O'Connor as global CEO in September 2026 while co-founder Byron Kennedy relocated to the United States.