Researchers from the University of Massachusetts Amherst have successfully demonstrated a pioneering use of 3D printing to repair aging infrastructure, applying a method called cold spray to a decommissioned bridge in Great Barrington, Massachusetts.
The effort, described as a first-of-its-kind proof-of-concept repair on a bridge, may offer a faster and less disruptive solution to the pressing challenge of deteriorating US bridges.
Led by UMass Amherst in partnership with the Massachusetts Institute of Technology (MIT) Department of Mechanical Engineering, the demonstration took place last month on the red bridge, formerly known as the Brown Bridge.
“This is a huge milestone,” said Simos Gerasimidis, associate professor of civil and environmental engineering at UMass Amherst.
“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.”
Gerasimidis has been involved in bridge deterioration research for over a decade and has worked closely with state transportation departments on infrastructure resilience.
Cold spray has been successfully used in sectors such as aerospace and marine engineering but had not yet been applied to bridges. Unlike conventional repair methods, which often require extensive traffic shutdowns, this technique allows for repairs with minimal disruption.
“This will allow us to [apply the technique] on this actual bridge while cars are going [across],” Gerasimidis noted.
The project was supported by the Massachusetts Department of Transportation (MassDOT), the Massachusetts Technology Collaborative’s Center for Advanced Manufacturing, the U.S. Department of Transportation, and the Federal Highway Administration.
The Massachusetts Manufacturing Innovation Initiative also provided key equipment for the demonstration.
John Hart, Class of 1922 Professor at MIT’s Department of Mechanical Engineering, said the project exemplifies how advanced manufacturing can meet urgent infrastructure needs.
“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,” Hart said.
To support the cold spray application, researchers used 3D LiDAR scanning to assess the bridge’s condition and identify precise locations for targeted repair. Gerasimidis explained that combining advanced scanning with additive manufacturing makes it possible to “give this bridge another 10 years of life,” extending its usability while avoiding full-scale replacement.
According to the 2025 Report Card for America’s Infrastructure, 49% of the nation’s bridges are in “fair” condition and nearly 7% are considered “poor.”
In Massachusetts, about 9% of the 5,295 bridges are structurally deficient. The cost to address these needs nationwide is estimated at over $191 billion.
Once the red bridge is dismantled, the repaired beams will be transported to UMass Amherst for further evaluation.
Researchers will test the adhesion of the deposited steel powder, assess whether additional corrosion occurred after application, and examine the mechanical strength of the repaired structure under controlled conditions.
“This is a very Massachusetts success story,” Gerasimidis said, citing the collaboration between public agencies and academic institutions.
“It involves MassDOT being open-minded to new ideas. It involves UMass and MIT putting [together] the brains to do it. It involves MassTech to bring manufacturing back to Massachusetts. So, I think it’s a win-win for everyone involved here.”
The research team acknowledged MassDOT’s Highway Division and the Research and Technology Transfer Program for technical guidance and funding support throughout the project.
