Fabrisonic LLC: Innovative 3D Metal Printing Without Melting

Fabrisonic LLC is an innovative manufacturing technology company that provides 3D metal printing services in a wide range of metals through the patented Ultrasonic Additive Manufacturing (UAM) process. As a technology focused small business, Fabrisonic has the technical capability and agility needed for the emerging fast-paced manufacturing world. The commitment to quality is evidenced through several quality awards from industrial customers.

Columbus, OH-headquartered Fabrisonic’s provides its innovation for aerospace metals, aluminum and copper with a low‐temperature Ultrasonic Additive Manufacturing (UAM) technology. This one-of-a-kind hybrid technology allows its clients create structures impossible with traditional subtractive manufacturing alone – driving improvements in performance, quality and cost.

UAM relies on solid-state ultrasonic bonding with no change to metal microstructure. The bond permits joining of dissimilar metals without the metallurgical mismatch issues seen in other additive processes. A wide range of material combinations can be printed in a single part opening the design space to enable property gradients and engineered material.

“Fabrisonic’s 3D metal printing process creates complex components that have unique features and attributes not possible with traditional manufacturing techniques.”

Origin Story

The company was formed in 2011 to consolidate the intellectual property of EWI, an Ohio based 501c(3) research organization, and a Michigan based for profit company, Solidica. Fabrisonic controls nine patents covering all aspects of UAM. Fabrisonic’s first machine, the SonicLayer 7200 was built prior to 2011 through an Ohio Third Frontier technology development program. Following the success of its first machine, Fabrisonic developed and built a smaller, research-platform machine, the SonicLayer R200, and a mid-sized production model, the SonicLayer 4000. These machines help to shorten lead times for prototypes and production parts that we make for both commercial and government partners.

Fabrisonic focuses on “impossible” metal solutions that solve both common and complex engineering problems. Typical client solutions include:

• 3D printing dissimilar metals to produce a new material with custom mechanical, electrical, or thermal properties.
• 3D printing aluminum and copper heat exchangers with novel high efficiency internal features.
• 3D printing metal components that are enhanced with embedded sensors and electronics.

Printing the ‘Impossible’

Fabrisonic’s 3D metal printing process creates complex components that have unique features and attributes not possible with traditional manufacturing techniques. There are three main characteristics of the UAM process that customers frequently gravitate to which form the basis of many of the applications.

The company focuses on developing ground-breaking solutions for its customers. Their 3D metal printing process creates ‘impossible designs’ with unique features and attributes not feasible with traditional manufacturing techniques, or even other additive processes.

3D printing has already had a disruptive impact on the world of manufacturing allowing parts made faster, made with never before seen complexity, and brought to market in less time.

Ultrasonic Additive Manufacturing (UAM), developed by Fabrisonic, combines a unique room-temperature metal deposition process with the ease of traditional CNC milling. Our patented ultrasonic ‘print head’ is integrated into 3-axis mills to create a hybrid additive-subtractive process. Swapping from additive to subtractive is as easy as doing a tool change.

UAM combines the advantages of additive and subtractive fabrication approaches to allow complex 3D parts to be formed with high dimensional accuracy and smooth surfaces, including objects with complex internal passageways. ASTM International (American Society for Testing and Materials) defines Additive Manufacturing as the “process of joining materials to make objects from 3D model data usually layer upon layer, as opposed to subtractive manufacturing methodologies much like CNC milling.” Synonyms include: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing and free-form fabrication.

While not formally defined under ASTM terminology, hybrid additive is generally considered to be a combination of additive (3D printing) and subtractive (CNC milling) technologies in a single machine. For instance, the SonicLayer 4000, starts off life as a large three-axis mill to which we integrate our patented ultrasonic welding head. The system builds up to near-net shape using ultrasonic welding and completes fine detail through the use of onboard CNC milling.

Fabrisonic provides expertise in both the development and fabrication of metal components with sensors embedded exactly where measurements are needed. Need to measure strain three inches inside of an aluminum wing? Want to monitor temperature on the ID of process piping? Fabrisonic’s UAM provides 3D printing of metal near room temperature allowing a multitude of sensors to be printed ANYWHERE in solid metal parts.

About the Leader

Mark Norfolk, PE – President & CEO

With over twenty years of experience in manufacturing, R&D, and shop floor management, Mr. Norfolk leads Fabrisonic in the commercialization of Ultrasonic Additive Manufacturing (UAM) Technology. Mr. Norfolk led EWI’s development and research into UAM for four years leading up to the inception of Fabrisonic and has been with the company ever since. Prior to joining EWI, Mr. Norfolk held numerous manufacturing and management positions at Deere & Company in Moline, Il. He holds an MBA from The University of Iowa and a Bachelor’s of Science in Welding Engineering from The Ohio State University.

“Columbus, OH-headquartered Fabrisonic’s provides its innovation for aerospace metals, aluminum and copper with a low‐temperature Ultrasonic Additive Manufacturing (UAM) technology.”