Spray forming is a multiphase fabrication technology in which a spray of finely atomized liquid droplets is directed onto a suitably shaped substrate or pattern to produce a coherent, near-net-shape deposit The technology can simplify materials processing where simultaneously improving product quality. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray-forming technology for producing near-net-shape solids and coatings of a variety of metals, polymers, and composite materials using de Laval nozzles. Here we briefly describe the flow field characterization and atomization behavior of liquid metals in linear de Laval nozzles, and illustrate their versatility by summarizing results from three spray-forming programs. In one program, low-carbon steel strip >0.75 mm was produced. In another program, polymer membranes [approximately] 5 [mu]m thick were spray formed. Finally, recent results in spray forming molds, dies, and related tooling for rapid prototyping are described
