Fabrisonic
Fabrisonic is a US metal additive manufacturing company that uses patented Ultrasonic Additive Manufacturing (UAM) to produce solid-state welded metal parts for aerospace (Boeing, NASA JPL), EV battery manufacturers, energy, and research laboratories through custom part production and SonicLayer equipment sales.
- Company typePrivate
- Founded2011
- HeadquartersColumbus, United States
- Headcount1–10
- GTM typeB2B
- OfferingHardware or Manufacturing
What Fabrisonic does
Fabrisonic is a US-based metal additive manufacturing company specializing in Ultrasonic Additive Manufacturing (UAM), a patented solid-state process that welds successive layers of metal foil (0.005-0.010 inches thick) using high-frequency ultrasonic vibrations at temperatures well below melting points (below 250°F for aluminum), integrated with CNC machining in a single hybrid additive/subtractive platform. The company's SonicLayer machine family (1200, 1600, 4000, and 7200) supports build envelopes up to 6ft x 6ft x 3ft at rates of 15-30 cubic inches per hour, with tolerances of ±0.0005 inches and helium leak test performance down to 10⁻⁹ std cc/sec. UAM uniquely enables joining of dissimilar metals (Al/Cu, Al/Ti, Ni/Ti, Al/Invar, etc.) without brittle intermetallics and embedding of fiber optics, strain gauges, thermocouples, and electronics into fully-dense metal parts.
The company serves aerospace and space customers (Boeing, NASA JPL for heat exchangers and thermal management), electric vehicle battery manufacturers (Wiegel Tool Works partnership producing 35 million busbar parts in 2023), energy/nuclear labs, universities and research institutions, and other 3D printing OEMs. Fabrisonic generates revenue through a combination of custom part production services (from single prototypes to serialized high-volume runs in its 25,000 sf manufacturing space), SonicLayer equipment sales, embedded-sensor/smart-part contract manufacturing, and Design-for-UAM engineering consulting. Customers are engaged through a quote-based application review process typical of enterprise field sales. Fabrisonic was founded in 2011 after spinning out of EWI, opened a new 30,000 sq ft Columbus, Ohio headquarters in March 2024, transitioned to a new CEO (Jason Riley) in September 2024, and was acquired by United Performance Metals, an O'Neal Industries affiliate, in March 2025.
Fabrisonic firmographics
Firmographics- Name
- Fabrisonic
- Legal name
- Fabrisonic LLC
- Website
- https://fabrisonic.com
- Company type
- Private
- Founded year
- 2011
- Operating status
- Operating
- Headcount range
- 1–10 employees
- Short description
- Fabrisonic is a US metal additive manufacturing company that uses patented Ultrasonic Additive Manufacturing (UAM) to produce solid-state welded metal parts for aerospace (Boeing, NASA JPL), EV battery manufacturers, energy, and research laboratories through custom part production and SonicLayer equipment sales.
- Ownership category
- akta.pro rank
Where Fabrisonic is headquartered
LocationHeadquarters
- HQ city
- Columbus
- HQ country
- United States
- HQ region
- North America
Offices1 record
Markets served
Fabrisonic business model
Business model- GTM type
- B2B
- Offering type
- Hardware or Manufacturing
- Cost components
- Personnel, Technology or R&D, Operations, Infrastructure, Supply Chain, Marketing or Sales
Revenue model
- Part Production Services: Short-run to high-volume production of custom metal parts using UAM technology. From single custom parts to millions per year. Includes serialized part production with 25,000sf of manufacturing space for bridging customers from prototype to mass production.
- SonicLayer UAM Equipment Sales: Sale of SonicLayer additive manufacturing machines including SonicLayer 4000, 7200, 1200, and 1600 models with varying build envelopes from 24in x 36in to 6ft x 6ft x 3ft.
- Materials R&D and Prototyping Services: Research and development services for novel material combinations, custom heat exchangers, embedded sensors, and dissimilar metal applications. Includes design for UAM training sessions.
- Design for UAM Consulting: Engineering partnership to guide customers through Design for UAM process, including in-person or virtual training sessions for customer engineering and design teams.
Pricing tiers
| Model | Billing | Price |
|---|---|---|
| Other | Multi-year contract | Custom project-based pricing |
Go-to-market motion2 records
Distribution channels3 records
Marketing channels6 records
Fabrisonic product offering
Product offeringCore offering
Fabrisonic designs, manufactures, and operates Ultrasonic Additive Manufacturing (UAM) systems — a patented low-temperature, solid-state metal 3D printing process that welds successive layers of metal foil via ultrasonic vibrations and integrates CNC subtractive machining in a single machine. The company sells SonicLayer UAM equipment and provides custom part production, prototyping, and Design-for-UAM engineering services to aerospace, space, energy, and EV battery manufacturers.
Differentiator
Problem solved
Functional benefit
Products and services
- SonicLayer 4000 UAM Machine Ultrasonic Additive Manufacturing machine with a 24in x 36in build envelope, 20-position automatic tool changer, and industry-standard G-code programming, sold to manufacturers for in-house UAM production.
- SonicLayer 7200 UAM Machine Large-format Ultrasonic Additive Manufacturing machine accommodating parts up to 6ft x 6ft x 3ft, installed at Fabrisonic's Lewis Center, Ohio headquarters and offered as part of the SonicLayer equipment line.
- SonicLayer 1600 UAM Machine SonicLayer UAM machine introduced at Fabrisonic's new Columbus, Ohio headquarters grand opening, expanding the smaller-format UAM equipment line.
- SonicLayer 1200 UAM Machine Compact SonicLayer UAM machine from the SonicLayer product family, used in the development of bus bar and heat exchanger production workflows.
- SmartPlate Instrumented Build Plates UAM-manufactured build plates embedded with optical strain gauges, thermal sensors, thermocouples, and vibration sensors that enable real-time in-process quality monitoring during additive manufacturing builds.
- Custom UAM Part Production Services Contract manufacturing of custom multi-material metal parts using UAM, ranging from single prototypes to millions of parts per year, supporting customers across aerospace, space, energy, and EV battery applications.
- Materials R&D and Prototyping Services Research and development services that explore novel material combinations, custom heat exchangers, embedded sensors, and dissimilar metal applications using the UAM process for customers in aerospace, energy, and research sectors.
- Design for UAM Consulting and Training Engineering consulting and training offering that partners with customer engineering and design teams to teach Design for UAM methods, available as in-person or virtual training sessions.
Quantifiable outcome
- 30+ million parts produced using UAM technology
- +4 more outcomes
Companies that use Fabrisonic
Customer profileNamed customers4 records
Segments5 records
Ideal customer profiles4 records
Fabrisonic technology and API
TechnologyTechnology focussed Yes
API detail
- Has API
- No
- API docs
- API detail
Core technology
AI maturity
App detail
Feature6 records
Fabrisonic partnerships and signals
Strategic signalPartnerships
Six partnerships are on record, tiered core and minor.
- United Performance Metals (UPM)coreUnited Performance Metals, an O'Neal Industries affiliate, acquired Fabrisonic LLC in March 2025. This strategic acquisition enhances UPM's capabilities in advanced manufacturing and expands its portfolio of innovative solutions. Fabrisonic joins UPM's specialty processing facilities including Precision Thin Strip, UPM Advanced Solutions, and Precision Cold Saw Cutting and Grinding.
- Additive Manufacturing Production Club (AMPC)minorMembership in AMPC recognized at AM Industry Awards during RAPID+TCT 2024. Club requirements include producing more than 50k parts using additive manufacturing technology.
- Wiegel Tool WorkscorePartnership from 2019-2022 developed fully automated, high-volume production UAM machines for EV battery applications. Collaboration leveraged Wiegel's expertise in high-volume stamping and Fabrisonic's unique welding technology to produce busbars for EV manufacturers. Produced 35 million parts in 2023 alone.
- O'Neal Industries (ONI)coreO'Neal Industries is the parent company and nation's largest family-owned network of metals service centers with over 80 specialized facilities in North America, Europe, and Asia. Sales of $3.4 billion in 2024. Includes affiliates: Leeco Steel, TW Metals, O'Neal Steel, United Performance Metals, and others.
- EWIcoreFabrisonic was originally a division of EWI before becoming independent in 2011. EWI is a leader in advanced manufacturing and engineering solutions headquartered in Columbus, Ohio. Henry Cialone serves as Fabrisonic's Board Chairman and CEO of EWI.
- America MakesminorAmerica Makes is the National Additive Manufacturing Innovation Institute. Fabrisonic is a member and displays the America Makes logo on their website.
Scale indicators5 records
Recent moves6 records
Expansion highlights5 records
Fabrisonic competitors and assessment
Company assessmentDirect peers
- Velo3D: Metal additive manufacturing equipment and parts supplier serving aerospace, space, and energy customers; competes for the same industrial AM applications as Fabrisonic's UAM.
- Markforged: Metal and composite 3D printing platform with direct part production and equipment sales; overlaps Fabrisonic in delivering industrial metal AM solutions to enterprise customers.
Emerging players
- Optomec: Specialty metal AM vendor using DED and aerosol jet printing for industrial applications including electronics packaging; partially overlaps Fabrisonic in metal AM for advanced applications.
- Sciaky: Provider of electron beam additive manufacturing (EBAM) systems for large metal parts in aerospace and defense; competes in the same aerospace/space customer set as Fabrisonic.
Broad incumbents
- DMG MORI Additive Manufacturing: Metal powder bed fusion and hybrid AM systems integrated into a global machine tool OEM; competes with Fabrisonic in hybrid additive/subtractive metal manufacturing.
- EOS GmbH: One of the largest metal AM equipment and materials suppliers globally with deep aerospace and industrial customer penetration; competes with Fabrisonic's UAM at the application level.
- SLM Solutions: Industrial metal AM machine maker focused on aerospace, automotive, and energy; competing metal AM modality for aerospace and EV components Fabrisonic also targets.
- 3D Systems: Large broad-line 3D printing company with metal AM equipment and services for aerospace and industrial customers; an adjacent incumbent in Fabrisonic's served market.
- TruPrint (Trumpf): Industrial laser metal AM systems from Trumpf, a large established German manufacturing conglomerate; competes with Fabrisonic for industrial metal AM customers and applications.
Others
- Stratasys: Polymer-focused 3D printing platform with growing metal AM footprint via partnerships; thematically adjacent to Fabrisonic's industrial AM services offering.
Market position
Strengths5 records
Weaknesses5 records
Competitive moat5 records
Key risks6 records
Key highlights7 records
Customer concentration
Fabrisonic social profiles
Digital presenceFabrisonic financial estimates
Financial estimateRevenue estimate
Valuation estimate
Fabrisonic leadership team
Management profileNumber of profiles
Profiles11 records
Fabrisonic funding detail
Funding detailFunding overview
Funding rounds
Investors
Funding detail is available on the Subscription and Enterprise plan.Contact sales →
Fabrisonic M&A and investment
M&A and investmentM&A
Investments
M&A and investment is available on the Subscription and Enterprise plan.Contact sales →
Frequently asked questions about Fabrisonic
What does Fabrisonic do?
Fabrisonic designs, manufactures, and operates Ultrasonic Additive Manufacturing (UAM) systems — a patented low-temperature, solid-state metal 3D printing process that welds successive layers of metal foil via ultrasonic vibrations and integrates CNC subtractive machining in a single machine. The company sells SonicLayer UAM equipment and provides custom part production, prototyping, and Design-for-UAM engineering services to aerospace, space, energy, and EV battery manufacturers.
Is Fabrisonic a public or private company?
Fabrisonic is a private company. It is classified as corporate owned and is currently operating.
When was Fabrisonic founded?
Fabrisonic was founded in 2011. It employs 1 to 10 people.
Where is Fabrisonic based?
Fabrisonic is headquartered in Columbus, United States, in the North America region.
How does Fabrisonic make money?
Four revenue lines are on record. Part Production Services are the primary driver. The others are sonicLayer UAM Equipment Sales, materials R&D and Prototyping Services and design for UAM Consulting.
Who are Fabrisonic's main competitors?
Direct peers on record are Velo3D and Markforged. Emerging players are Optomec and Sciaky. Broad incumbents are DMG MORI Additive Manufacturing, EOS GmbH, SLM Solutions, 3D Systems and TruPrint (Trumpf). Stratasys is listed as an others.
Does Fabrisonic have an API?
No public API is recorded for Fabrisonic.