As more than half of U.S. bridges show signs of deterioration, a research team led by the University of Massachusetts Amherst and MIT has successfully tested a 3D printing repair method on a corroded bridge in western Massachusetts.
The pilot project focused on using “cold spray” technology—a process that accelerates powdered steel in heated gas and applies it in layers to restore strength and thickness to damaged beams. The on-site repair, conducted on a small bridge in Great Barrington, marks one of the first known applications of this method in field conditions for highway infrastructure.
“This is a huge milestone,” said Simos Gerasimidis, associate professor at UMass Amherst, in a statement. “We now see a path to a faster, less costly, and less disruptive solution.”
According to the American Society of Civil Engineers’ 2025 Infrastructure Report Card, 49.1% of U.S. bridges are in “fair” condition and 6.8% are rated “poor.” The projected cost to fix them all exceeds $191 billion.
Unlike ships or airplanes, bridges cannot be moved to a repair facility, making field-ready technology essential. The team’s solution is designed to minimize traffic disruption while reinforcing aging infrastructure.
MassDOT identified the bridge for the test and supported the demonstration through its Research and Technology Transfer Program. The effort also received backing from MassTech’s Center for Advanced Manufacturing.
After the bridge is demolished in the coming years, UMass researchers plan to recover the sprayed beams for lab testing to assess long-term performance.
The project reflects a multi-agency partnership involving UMass, MIT, MassDOT, MassTech, the U.S. Department of Transportation and the Federal Highway Administration.
Source: MIT.edu, 3Dprinting.com
