Plasma Processes Llc

Founded in 1993 and located in Huntsville, AL – “The Rocket City” – Plasma Processes is an AS9100D:ISO 9001:2015 certified provider of high-performance materials, coatings, and net-shape structures designed for the most extreme environments. We deliver advanced material solutions to aerospace, defense, space, energy, power generation, oil & gas, semiconductor, and other demanding industries. Our expertise spans high and ultra-high temperature materials, including refractory and platinum-group metals such as iridium, rhenium, tungsten, and molybdenum, along with oxides and ceramics. These materials are applied as specialty coatings or fabricated into custom parts to address thermal and oxidation protection, radiation shielding, wear and corrosion resistance, emissivity control, electrical isolation, and dimensional restoration. Capabilities include powder alloying and spheroidization (PAS), a full metallurgy laboratory, arc-jet testing, advanced machining with 5-axis and EDM systems, and multiple deposition processes including plasma spray, cold spray, and wire-arc spray. In 2024, Plasma expanded facilities to add more walled areas for special programs, precision post-processing and machining, and assembly operations. Our experienced team of engineers and subject matter experts (SEM's) have decades of experience maturing technologies from basic research through system qualification and into high-rate production. Our solutions are for products going into extreme conditions, whether that's for commercial or government work. We partner with industry, academia, and research laboratories for enhancing next generation technologies. Please visit us at https://plasmapros.com/ or email us at info@plasmapros.com. Note: Our propulsion division, Rubicon Space Systems, is achieving great milestones for commercializing the green propellant, ASCENT, through our product line of thrusters and propulsion systems. Please visit their website at