U.S. manufacturer Skuld-led R2R project has filed a patent application covering the direct casting of wrought aluminum alloys, including 6061 and 7075, from scrap. The process achieves forging-equivalent mechanical properties solely through casting and heat treatment, without traditional rolling or forging. The project uses AI-assisted spark testing for rapid identification of unknown scrap alloy compositions, and employs an AMEC (Additive Manufacturing Evaporative Casting) process to produce expendable pattern casting molds via 3D printing, eliminating hard tooling as well as associated lead times and capital costs. A compact, portable casting system has also been developed for on-demand production in logistics-constrained environments, targeting field manufacturing capabilities for military and emergency response scenarios.