Another steel spray process is currently in development at Idaho National Environmental and Engineering Lab (INEEL) called Rapid Solidification Process (RSP).

It differs from other sprayed metal processes in that it can deposit hundreds of pounds of material per hour, while the conventional wire-feed systems deposit approximately 15.4 lbs. (7 kg) per hour. This means that, potentially, the RSP process could be used to build the entire tool as opposed to a thin shell that requires back filling.

Global Metal Technologies, Inc. (Solon, Ohio) has entered into a Cooperative Research and Development Agreement (CRADA) with INEEL (Idaho Falls, Idaho) and intends to use RSP tooling in its production facility. The company claims that RSP tooling lasts 20 percent longer than conventional dies and can lower tooling costs by 20 percent.
INEEL has been successful in spraying H13 and P20 tool steels onto a ceramic take-off of an RP master pattern. A limitation at present is the size limitation of about six inches (150 mm).