SOLID-STATE METAL MANUFACTURING
Friction Stir Deposition
Build, repair, and develop metal components through a controlled solid-state process that deposits and consolidates material without melting it.
A Solid-State Path to More Capable Metal Manufacturing
Friction Stir Deposition (FSD) is a metal additive manufacturing process that builds, repairs, and adds material to components layer by layer. Instead of melting the metal, the process uses friction and pressure to soften, stir, and consolidate the material in the solid state. This can help produce strong, consistent components with refined grain structure and low distortion.
PAR Systems and Enabled Engineering are collaborating to bring an integrated Friction Stir Deposition platform to market. The partnership combines Enabled Engineering’s patented SolidStir™ process with PAR Systems’ experience in friction stir welding, machine building, motion control, and critical-industry applications.
Together, the companies connect solid-state material deposition with production-ready equipment and system integration. The result is a practical path for manufacturers exploring new ways to build, repair, and improve metal components.
Key Advantages
• Reduce lead times for selected metal components
• Near-net-shape deposition with forged-like material properties
• Minimal post-processing, with additive and machining operations possible on one motion platform
• Retrofit capability for existing I-STIR, CNC and other motion systems
• Integrated motion, monitoring, and process control for production development
• Flexible feedstocks, including rod and reclaimed material pathways
How Friction Stir Deposition Works
Friction Stir Deposition builds metal components layer by layer without melting the material. A rotating tool generates frictional heat and intense mechanical stirring, which plastically deforms and consolidates the feedstock in the solid state. The result can include fully consolidated deposits, refined microstructures, strong interlayer bonding, and low residual stress. These characteristics can help reduce distortion and post-processing requirements.
Friction Stir Deposition is closely related to friction stir welding. Both processes use a rotating tool and frictional heat to shape and join metals without melting them, filler materials, or shielding gases. The key difference is how material is arranged. Friction stir welding joins two existing components along a joint line, while Friction Stir Deposition adds feedstock layer by layer onto a substrate to build, repair, or add material to a part.
PAR Systems brings extensive machine-building and application experience to friction stir processing, including the development of FSW systems and production-ready automation.
PAR Systems + Enabled Engineering
PAR Systems: Proven friction stir welding leader with decades of machine-building expertise.
Enabled Engineering: Developer of the patented SolidStir™ additive manufacturing and extrusion process.
Together: A strategic partnership and integrated path for maturing solid-state manufacturing toward commercial deployment. PAR Systems is the exclusive licensee of the technology.
Four FSD Pathways
Additive Manufacturing: FSD can build near-net-shape aluminum components layer by layer, reducing the amount of material that must be removed during machining. The process is suited to large or complex components where conventional casting, forging, or fusion-based additive methods may create cost, lead-time, or material-performance challenges.
Extrusion: Solid-state extrusion can transform metal feedstock, including chips, powders, or recycled material, into fully consolidated extrudates without melting. Lower processing temperatures, high material utilization, and the ability to produce complex or graded profiles create opportunities for more efficient manufacturing.
Recycling: FSD can support circular manufacturing approaches by using reclaimed feedstock such as machining chips or other metal scrap. Converting recovered material into useful components or extrusions may reduce material waste, improve feedstock utilization, and create new options for localized recycling.
Material Development: The process also creates a platform for developing new alloys, composites, dissimilar-material combinations, and gradient structures. Site-specific alloying and controlled process development may enable material properties and component designs that are difficult to achieve through conventional manufacturing.
Where FSD May Fit in Your Application
Potential application areas for Friction Stir Deposition include space launch, defense, and marine applications such as Navy ship repair. These environments can benefit from shorter lead times, material efficiency, repairability, production flexibility, and high-integrity metal components.
Whether FSD makes economic sense depends on part geometry, material, production volume, qualification requirements, and the total delivered cost of the current casting or forging route. PAR can help compare those factors with laser-based deposition and other solid-state additive processes.