VRC Metal Systems, LLC

VRC Metal Systems, LLC, a veteran-owned limited liability company and manufacturer headquartered in Box Elder, South Dakota, delivers cold spray technology systems, additive manufacturing equipment, and advanced materials processing solutions to the Department of Defense as a prime contractor (88% of recent awards) and as a subcontractor on defense R&D programs. The company competes predominantly full-and-open on defense contracts; its set-aside footprint is limited to small business SBIR and STTR research designations. VRC Metal Systems operates two named subsidiaries: H.F. Webster Engineering Services, Inc., a veteran-owned Subchapter S corporation, and Mid-America Aerotech, LLC, a veteran-owned limited liability company, both manufacturers of goods.

Customer concentration sits heavily with Navy and Army defense R&D. The top five customers account for 72% of recent awards by count and 97% by combined potential value. Naval Sea Systems Command leads by volume and dollars (20 awards, $85.6 million combined potential value), followed closely by Army Materiel Command Research Development and Engineering Command (20 awards, $68.2 million). Naval Air Warfare Center (10 awards, $10.6 million), Army Corps of Engineers Engineer Research and Development Center (6 awards, $3.1 million), and Department of Energy Office of Science (7 awards) round out the active set. The two rankings track closely — NAVSEA and RDECOM dominate both metrics, with NAVSEA's potential-value share anchored by a $62.1 million SBIR Phase III indefinite delivery contract for cold spray cell technology development and a $6.6 million Phase III delivery order for cold spray cell development and demonstration.

VRC Metal Systems holds three major prime contract vehicles. An Army RDECOM Indefinite Delivery Contract valued at $50 million (set-aside Total Small Business, STTR Phase III base contract through September 2028) carries nine task orders worth $10.3 million for scalable advanced manufacturing systems and processes. A Naval Air Warfare Center Blanket Purchase Agreement valued at $5 million (single-award, firm fixed-price, through December 2029) procures advanced manufacturing solutions and cold spray services. A Naval Air Warfare Center Basic Ordering Agreement (SBIR Phase III, $0 ceiling designation but reflecting $62.1 million in cumulative task orders) funds cold spray process development and ship and submarine maintenance support. Representative prime work includes a $5.11 million Army RDECOM modular-capable cold spray system procurement (September 2023), a $2.07 million Army RDECOM STTR Phase III delivery order for research and development services (September 2025), and two STTR Phase III delivery orders to Army RDECOM totaling $2.19 million and $1.6 million respectively for advanced manufacturing systems development (July–September 2025).

VRC's capability portfolio centers on cold spray repair and coating systems, additive manufacturing equipment (including the proprietary RAPTOR and Dragonfly systems), mobile manufacturing platforms, advanced materials processing, and R&D support for military infrastructure maintenance. The company also designs and manufactures cold spray system components, applicators, and enclosures. Recent contract scope spans cold spray cell technology development, bore coating system operation at Army arsenals, cold spray maintenance and calibration services, and naval and Army equipment upgrades. A $187,942 Naval Sea Systems Command purchase order (August 2025) covered procurement of a VRC Metal Dragonfly Cold Spray System with NRTL certification and technician setup. A $144,894 TACOM Life Cycle Management Command purchase order (February 2026) funded operation of the Advanced Bore Coating System at Watervliet Arsenal to coat one production gun barrel. A $29,442 Army purchase order (July 2025) covered site analysis and reporting services.

Activity has remained flat to slightly declining year over year — seven awards in 2022, ten in 2023, and sixteen each in 2024 and 2025 — with three awards recorded in 2026. Seven awards (combined potential value $9.4 million) reach ultimate completion inside the next twenty-four months and face recompete. In its subcontractor role, VRC delivers cold spray equipment, materials processing support, and advanced manufacturing solutions to Leidos (research and development for novel explosives in advanced multi-purpose munitions, two sub-awards in March and April 2025), University of Dayton (additive manufacturing and cold spray support under EPSE IV and SABR-C programs, multiple sub-awards from 2023 to December 2024), Deloitte Consulting (maritime submarine workforce and manufacturing technology development, May 2026), South Dakota School of Mines & Technology (mobile cold spray system capability for Rapid Sustainment Office, August 2025), and several others including Triad National Security (Los Alamos National Laboratory operations competition), National Center for Defense Manufacturing and Machining (Letterkenny Army Depot modernization), and Rolls-Royce North American Technologies (ATTAM propulsion program materials). The company also acts as recipient on federal grants from the Department of Energy Office of Science, including a $199,925 Project Grant (July 2024 through April 2025) under CFDA 81.049 for cold spray additive manufacturing for power system design and life extension, and support for a Department of Energy Office of Science cooperative agreement on additive manufacturing and advanced materials processing for defense (awarded April 2022, through September 2026). Recent prime research and development concentration falls under NAICS 541712 (Research and Development in Physical, Engineering, and Life Sciences except Nanotechnology and Biotechnology), with secondary footprint in manufacturing machinery and machine tool accessories.