Researchers from UMass Amherst and MIT have successfully applied 3D printing technology to repair a bridge in Great Barrington, Massachusetts. The test utilized a technique called cold spray, which involves spraying high-velocity metal powder particles to coat and restore sections of deteriorated beams. This demonstration marks the first known application of cold spray additive manufacturing on a bridge structure.
“Now that we’ve completed this proof-of-concept repair, we see a clear path to a solution that is much faster, less costly, easier, and less invasive,” said Simos Gerasimidis, associate professor of civil and environmental engineering at UMass Amherst. The project involved collaboration with the Massachusetts Department of Transportation, Massachusetts Technology Collaborative, the U.S. Department of Transportation, and the Federal Highway Administration.
The technique could help address America’s aging bridge infrastructure. According to the 2025 Report Card for America’s Infrastructure, 49% of the nation’s bridges are only in “fair” condition and 6.8% are rated “poor,” with projected restoration costs exceeding $191 billion. In Massachusetts alone, about 9% of the state’s 5,295 bridges are structurally deficient.
One significant advantage of the cold spray method is minimal traffic disruption during repairs. The process is complemented by 3D LiDAR scanning that allows precise identification of corrosion areas and targeted material application. “By combining scanning with precise material deposition, we can be very targeted and say, ‘we’re going to print here and here and here and we’re going to give this bridge another 10 years of life,’ which is huge,” Gerasimidis explained.
The red bridge in Great Barrington, formerly known as the “Brown Bridge” and built in 1949, is scheduled for demolition in a few years. After demolition, researchers plan to take the treated beams to their lab for further testing to evaluate the effectiveness of the repair technique. They will measure how successfully the deposited steel powder adhered to the structure and determine its mechanical strength properties.
John Hart, Class of 1922 Professor in the Department of Mechanical Engineering at MIT, noted: “This is a tremendous collaboration where cutting-edge technology is brought to address a critical need for infrastructure in the commonwealth and across the United States. I think we’re just at the beginning of a digital transformation of bridge inspection, repair and maintenance, among many other important use cases.”
Source: umass.edu