NON-TECHNICAL SUMMARY This research project explores a novel approach to creating stronger, more heat- and stress-resistant metals for extreme environments, including space, nuclear reactors, and advanced energy systems. A traditional method for strengthening metals rely on mixing in tiny particles that often degrade under harsh conditions. This project is developing an innovative technique that forms these particles during 3D printing itself, using reactive gases such as nitrogen and oxygen. These gases are injected into a pool of molten metal and chemically react to form durable ceramic particles inside the metal as it solidifies. The project is utilizing a process called Directed Energy Deposition, a type of additive manufacturing, to conduct this gas-metal reaction while printing parts layer by layer. This eliminates the need for expensive and energy-intensive pre-processing steps, such as mechanical alloying. The result is a more efficient and scalable method for producing metal components that are stronger, more durable, and suitable for extreme applications. The work supports national priorities in energy, defense, and manufacturing by reducing production costs and enabling the development of new high-performance materials. It also contributes to building a skilled STEM workforce. Each year, the project is engaging college and high school students in hands-on research at the University of Texas Rio Grande Valley. Outreach programs include dual-credit courses, K-12