Materials and Manufacturing

For over half a century, UTC has provided scientific and engineering expertise, program management, and specialized RDT&E capabilities for the defense materials and manufacturing community. Consistently ranked as one of the top small businesses supporting the Air Force Research Laboratory, Materials and Manufacturing Directorate, our strengths are particularly suited to the exploration and exploitation of materials, devices, and manufacturing techniques for the most demanding environments.

Our Team

UTC’s materials and manufacturing team consists of over 50 technical personnel. Highly experienced program managers and senior engineers lead all of our major RDT&E programs, supporting a staff of highly qualified scientists, engineers, and technicians working in both Government and UTC laboratories. Our team’s backgrounds span the breadth of materials science, metallurgy, physics, electrical engineering, chemistry, and other relevant disciplines, with three quarters having earned an advanced degree and half at the Ph.D. level. We also have certified NDT Level III technicians in ultrasonic testing (UT), magnetic particle testing (MT), liquid penetrant testing (PT), radiographic testing (RT), and electromagnetic testing (ET).

Our team is augmented by our network of collaborators, including leading universities, research institutes, small businesses, and manufacturers that we engage to provide specialized capabilities to meet our customer needs. UTC also owns and organizes many key technical exchanges, including the Defense Manufacturing Conference, Aircraft Structural Integrity Program Conference, Turbine Engine Technology Symposium, and Diminishing Manufacturing Sources and Material Shortages Conference. These and other interactions support regular engagement with our customers and collaborators.

Our Focus Areas

While our capabilities span the spectrum of materials and manufacturing topics, prominent areas of emphasis for current and future activity include:

  • Additive manufacturing techniques and new alloys
  • Multiscale and multiphysics materials/process modeling
  • Multifunctional materials and microsystems
  • Non-destructive testing and evaluation
  • Manufacturing readiness assessments
  • Industrial base analyses and cost-benefit analyses
  • Agile manufacturing methods and demonstrations
  • Machine learning and internet-of-things technologies

Our Facilities

In addition to activities in Government labs, UTC has dedicated research facilities outside Dayton, Ohio. Our lab currently features several unique and modular powder-bed fusion systems for additive manufacturing process and product development, funded through SBIR/STTR and other funding sources. These systems include a wide range of sensors and open-source computer control ideally suited for R&D project needs. Current focus areas include:

  • In situ sensing and control
  • Novel laser processing techniques
  • Hybrid additive/subtractive processing
  • Processing of niche/difficult materials
  • Test bed development and support


Materials Laser

 Laser Processing


Our current customers include the Air Force, Navy, and NASA, with material systems ranging from aerospace alloys, corrosion-resistant alloys, refractory metals, and advanced ceramics. We also have expertise in polymer-based and multi-material additive techniques for rapid prototyping and design demonstrations.