Big Metal Additive LLC

Big Metal Additive LLC is a Denver-based small disadvantaged business specializing in advanced metal additive manufacturing, particularly wire arc additive manufacturing (WAAM) and hybrid additive manufacturing processes. Registered in SAM.gov since February 2018, the company has established itself as a significant federal contractor providing research, development, and manufacturing services to defense and aerospace agencies. The firm focuses on the design and production of large-scale metal components and structures for space, aircraft, and defense applications, demonstrating expertise in complex federal contracting environments and research-focused initiatives.

The company has executed a substantial portfolio of federal contracts totaling over $8 million in prime contract awards across multiple defense and civilian agencies. Big Metal Additive LLC has received significant Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) Phase I and Phase II awards from the Air Force Research Laboratory, including contracts valued at $1.7 million for "Mission Optimized Service Spacecraft," $749,973 for "Optimized Additive Manufactured Aircraft Structure," and $109,980 for research on fracture and fatigue properties of aluminum alloys. The company also secured a $1.96 million SBIR Phase II contract from Naval Sea Systems Command in September 2025 for work supporting the Space-Based Infrared System High (SBIRS High) program. Additional contracts include a $99,925 Small Business Technology Transfer Phase I award from the Defense Logistics Agency for quality assessment methodologies in additive manufacturing, a $55,168.70 purchase order from the U.S. Coast Guard for housing seal delivery, and various other smaller firm-fixed-price purchase orders. The company holds a $750,000 blanket purchase agreement with the U.S. Army Corps of Engineers Engineer Research and Development Center for wire arc additive manufactured parts, and has been engaged as a subcontractor by the University of Dayton on defense projects. The majority of Big Metal Additive LLC's contract awards carry total small business set-aside designations, reflecting its status as a small disadvantaged business.

Big Metal Additive LLC has participated in federal grant programming through a cooperative agreement with the Air Force Research Laboratory. In August 2022, the company received a cooperative agreement award totaling $0.00 in documented ceiling value for research on "Optimized Isogrid Structures Using Hybrid Additive Manufacturing," with a performance period extending through April 30, 2024. This grant award, administered through the Shared Services Center, supported advanced manufacturing research aligned with the company's core competencies in hybrid additive manufacturing processes that combine additive and subtractive manufacturing methodologies. The cooperative agreement framework allowed Big Metal Additive LLC to collaborate with federal research institutions on technology development initiatives that advance additive manufacturing capabilities for aerospace and defense applications.

Big Metal Additive LLC holds a single-award blanket purchase agreement with the U.S. Army Corps of Engineers Engineer Research and Development Center valued at $750,000, established in September 2022 with an ultimate completion date of September 22, 2027. This master BPA facilitates the repetitive procurement of wire arc additive manufactured parts and services, with individual calls against the BPA valued up to $250,000 for additive manufacturing services performed at the company's Denver, Colorado facility. The BPA structure enables the Engineer Research and Development Center to procure customized metal components, including connector arms, sector gears, and other mechanical parts manufactured from high-strength low alloy steel using WAAM processes without requiring separate competitive solicitations for each requirement. As a single-award, non-set-aside contract vehicle, the BPA demonstrates the Army Corps of Engineers' confidence in Big Metal Additive LLC's capability to meet specialized additive manufacturing requirements, and the company has already exercised multiple calls against this agreement for specific components supporting ERDC research programs.