The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase I project is the development of a new type of metal 3D printing technology that is significantly more accessible, compact, and safer than current systems. Today, metal 3D printing is largely restricted to major players due to high equipment costs, complex infrastructure needs, and the safety hazards of using metal powders. This project introduces a drop-on-demand liquid metal printing process that uses solid wire as feedstock, simplifying the system’s architecture and its overall operations, eliminating the barriers imposed by current systems. By making high-quality metal printing accessible to small and medium-sized businesses, research labs, and universities, this innovation will accelerate technological innovation across the nation. The initial market will be applying coatings to industrial components, a billion dollar opportunity. Success in this niche will pave the way for expansion into the rapid prototyping and small-batch production markets for more complex components. The business model is based on selling low-cost, user-friendly printers that can operate in a standard office or lab environment, providing a durable competitive advantage and enabling widespread adoption of this critical manufacturing capability. This serves the national interest by fostering innovation, onshoring metal manufacturing, and thus enhancing U.S. competitiveness. This Small Business Innovation Research