Researchers at New Mexico State University (NMSU) have developed a molten metal jet additive manufacturing process that can convert recycled materials such as aluminum scrap directly into high-quality components. The technology separates melting from deposition, improving productivity and broadening the range of feedstock while avoiding the flammability, explosion risk, and transportation difficulties of traditional spherical metal powders. Using a multi-nozzle array combined with advanced modeling, it boosts throughput without compromising part quality. The project has received nearly $3 million in funding from the U.S. National Science Foundation, led by the Rochester Institute of Technology. This technology is particularly critical for scenarios where raw materials are hard to obtain in commercial and defense supply chains—such as military bases and remote areas—enabling on-demand manufacturing of key components and supporting multi-material smart components with wires directly embedded into structures.