March 2025 – U.S.-based specialty metals company United Performance Metals (UPM) has announced the acquisition of Fabrisonic, an innovative firm specializing in ultrasonic welding technology. This advanced technique enables 3D printing of multi-material gradient components and the integration of sensors within complex structures. The acquisition not only expands UPM’s technological portfolio but also injects new momentum into the additive manufacturing sector.
Advantages and Applications of Ultrasonic Welding Technology
Ultrasonic welding is a low-temperature solid-state process that offers distinct advantages over traditional additive manufacturing methods such as laser or electron beam technologies. By preserving the intrinsic properties of materials and allowing for direct embedding of circuits and sensors within components, this technique opens new doors for complex engineering applications.
For example, Fabrisonic’s ultrasonic welding technology enabled the production of an aluminum heat exchanger for NASA’s Jet Propulsion Laboratory, eliminating the need for thermal interfaces and additional hardware. As a result, the heat exchanger is 30% lighter and 30% more efficient than conventionally manufactured counterparts.
Strategic Impact of the Acquisition
UPM’s acquisition of Fabrisonic marks a deeper integration of metal services with additive manufacturing technologies. Although ultrasonic welding remains a niche technology in the market, its immense potential in specialized fields such as defense, aerospace, and high-end manufacturing cannot be overlooked. By incorporating Fabrisonic’s expertise, UPM enhances its innovation capabilities and strengthens its positioning in high-value-added sectors.
This acquisition also sends a strong message to the additive manufacturing industry: as market demands evolve and technology advances, even niche solutions can carve out a significant role. With its low-temperature processing, material compatibility, and multifunctionality, ultrasonic welding holds unparalleled advantages in complex structure manufacturing and sensor integration. As more companies invest in this technology, its growth potential is set to expand significantly.
In summary, the UPM-Fabrisonic partnership represents a win-win collaboration, driving technological advancement and setting a new benchmark for cross-industry integration.
About United Performance Metals (UPM)
UPM, a subsidiary of O’Neal Industries, is a U.S.-based specialty metals service provider. The company offers a full suite of metal processing services, including refurbishing LPBF (Laser Powder Bed Fusion) build plates, supplying wire feedstock and LPBF powders, and providing value-added services such as deburring, heat treatment, and packaging. By managing non-core manufacturing activities, UPM helps its clients reduce operational costs while maximizing efficiency and profitability.
About Fabrisonic
Originally a subsidiary of Edison Welding Institute (EWI), Fabrisonic is renowned for its ultrasonic welding technology, which enables solid-state bonding at low temperatures. Unlike traditional 3D printing techniques that involve extreme heat, this method preserves material integrity while allowing the combination of dissimilar materials like copper and aluminum. Fabrisonic’s technology also facilitates sensor embedding within components and can manufacture gradient structures up to 6 feet × 6 feet in size.
