Researchers led by C. Jacob Williamson from the United States published a study in May 2026 exploring the influence of geometry on residual stress in cold spray additively manufactured AA6061 aluminum alloy. They fabricated aluminum components with varying wall thicknesses and shapes, measuring internal stress distributions. The experiments achieved deposition rates exceeding 750 g/h, with no cracks or delamination. Neutron residual stress measurements revealed a maximum tensile stress of 41 MPa at the substrate interface and a maximum compressive stress of -35 MPa within the cold spray material. Cylindrical components showed higher tensile stress at the outer diameter than internally, while stress differences between walls of varying thicknesses were minimal. Cold spray additive manufacturing technology is transitioning from solid-state coatings to full additive manufacturing. The process can achieve deposition rates over 50 kg/h without melting the feedstock, suitable for material systems such as copper, aluminum, and refractory metals. Current challenges in component-level manufacturing include fundamental issues like defect modeling. Low residual stress and weak geometric dependence indicate that larger AA6061 components can be fabricated without failure risk. The study also found, through in-situ coating property measurements, that deposition stress decreases with increasing layer thickness. This provides key insights into understanding stress evolution in cold spray additively manufactured components.