[Source: NASA]
Preeti Sulibhavi and Jacob Nolan underscore how Ross Precision Manufacturing is transforming the copper industry through 3D printing, sustainable design, and respect for cultural heritage.
Ross Precision Manufacturing of Green Island, New York, brings with it over 80 years of expertise in precision machining and fabrication for aerospace, defense, and alloy melting industries. The company operates massive CNC machine centers, parts over 200 inches in diameter, alongside welding and fabrication operations. Now, they are expanding into additive manufacturing, specifically metal 3D printing, to enhance their copper capabilities in ways that traditional machining alone, cannot.
Revolutionizing Copper Components
Copper’s unmatched thermal conductivity makes it ideal for crucibles, molds, and melting hearths. Yet its hardness and complexity have historically challenged machinists. Ross Precision embraces 3D printing to produce copper components featuring intricate internal cooling channels and lattice structures. This design flexibility allows faster prototyping, reduced material use, and superior performance compared to conventional methods.
Innovation Backed by Funding
The company’s hybrid manufacturing efforts were spotlighted in a recent New York State FuzeHub Innovation Fund video by Jeff Lawrence. In the feature, Ross received funding aimed at combining large-format CNC machining with copper 3D printing. Their Green Island facility is now equipped to rapidly iterate through complex copper parts, making them a regional leader in next – generation metal manufacturing.
Supreme Court Approves New Copper Mine
Meanwhile, national attention has turned to copper mining in Arizona. On May 27, 2025, the US Supreme Court declined to hear Apache Stronghold’s appeal to block Ross’s competitor, Resolution Copper’s project at Oak Flat, a site sacred to the San Carlos Apache Tribe located in Tonto National Forest. This effectively lets a lower court decision stand, approving the 2400-acre transfer once a final environmental impact statement is issued. The projected mine would produce an estimated 40 billion pounds of copper and contribute approximately US$1 billion annually to Arizona’s economy.
Justices Gorsuch and Thomas dissented, with Gorsuch calling the refusal to hear the case a grievous mistake that disregards tradition and religious rights protected under the Religious Freedom Restoration Act. Project proponents argue that advancing domestic copper production is critical to supply chains and infrastructure. Critics argue that mine would destroy a spiritual landscape and tradition that cannot be replaced.
A Responsible Alternative in Copper Manufacturing
Ross Precision Manufacturing’s work presents a more sustainable and respectful approach to copper usage. Instead of relying on massive, ecologically and culturally disruptive mines, they extract high value from existing metal through design innovation. Their models reduce waste, shorten lead times, and underscore the importance of responsible manufacturing. In contrast to destructive big mining practices, Ross showcases how regional manufacturing can meet demand without eroding heritage or the environment.
[Source: National Wildlife Federation]
Industry Giants Contrast: Freeport-McMoRan and Phelps Dodge
Freeport-McMoran is the world’s largest publicly traded copper miner, reporting approximately US$25.5 billion dollars in annual revenue for 2024, up about 11 percent from 2023. Its acquisition in 2007 of Phelps Dodge for nearly US$26 billion created a powerhouse that dominates copper, gold, and molybdenum production. Before being absorbed, Phelps Dodge itself generated nearly Us$12 billion in revenue in 2006, with vast mining operations across North America. These industry giants illustrate the immense scale and impact of global copper extraction efforts, further underscoring why innovative, localized approaches like Ross Precision’s are vital in shaping a more responsible future for copper manufacturing.
Bridging Technological and Ethical Gaps
The story of copper is evolving. On one front, we see a battle over sacred land in Arizona, and on the other, a company in New York is using cutting-edge means to deliver copper solutions locally and responsibly. As demand for copper grows in energy, technology, and defense, Ross demonstrates that design innovation and precision manufacturing can help society meet industrial needs while respecting cultural and environmental concerns.
The Research & Development Tax Credit
The now permanent Research & Development Tax Credit (R&D) Tax Credit is available for companies developing new or improved products, processes and/ or software.
3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes can be included as a percentage of eligible time spent for the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software counts as an eligible activity. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion
Ross Precision Manufacturing is proving that there is a better path forward for the copper industry. By embracing innovation through 3D printing and maintaining a commitment to sustainable and ethical manufacturing, they stand as an example of how technology can reshape long-standing industries. As global demand for copper continues to rise, companies like Ross will play a crucial role in delivering smarter, more responsible solutions that honor both performance and principle.
