THE WAIT
Waiting on a forging die?
You do not need one. We build your part straight from your drawing.
Friction stir manufacturing · Youngstown, Ohio
Large Metal Structures, Built Without Melting
Send us your drawing. We build the part and ship it to you.
Got a Part Holding Up Your Program? Send It to Us.
A drawing, a STEP file, or a sketch and a size is enough. You will hear back within 3 business days.
contact@leapfast.com252 W Boardman St, Youngstown, OH 44503
Sound familiar?
If a Metal Part Is Stalling Your Program, You Are in the Right Place
You send the drawing. We handle the rest, from the first pass of metal to the part at your dock.
THE SIZE
Too big to cast or forge?
We build large structures one pass at a time, so the size of your part is not the limit.
THE METALS
Dissimilar metals that will not weld?
Friction stir joins metals that fusion welding cannot, and you get a sound joint.
THE DEFECTS
Porosity or hot cracking in your welds?
The metal never melts, so the defects that come from melting never form in your part.
Why LeapFast
What You Get When You Send Us Your Drawing
With Bobbin Friction Stir Deposition (B-FSD), you get:
- A process exclusively licensed from NASA, available to you through LeapFast
- The benefits of additive manufacturing for your massive metal structures
- Digital-twin-driven qualification and process monitoring behind your part
- No melting, so you get superior performance
- No machine to buy: you send the drawing, and we build and ship the part
NO DIE
Your Parts in Days to Weeks, Not Months
You skip the forging die or casting pattern, and the queue behind it.
STRONG
Forge-Equivalent Strength
Your part gets a refined microstructure with no solidification porosity or hot cracking.
QUICK
Built Quick, at Scale
Each pass deposits massive amounts of metal net-shape, so your hollow-form structures go up fast.
FLEXIBILITY
Designs You Could Not Make Before
The self-reacting process tool keeps loads low, so you can design complex curved structures with variable thickness.
Industries
Find Your Industry
Pick the one closest to your program and see how friction stir can work for you.
Your future in space
From the Launch Pad to the Lunar Surface
B-FSD began at NASA as a way to build large structures without endless lead times or poor performance. We are taking that process off-world, so your future program can build where it operates, including on moon bases.
Credentials
Why You Can Trust the Parts You Get
You get manufacturing built for energy efficiency and aerospace-level quality, by a team from NASA Marshall and Pacific Northwest National Laboratory.
- Licensed From NASA
- B-FSD, exclusively licensed · US Patent 12,157,179 B1
- AWS D17.3/4
- FSW and B-FSD procedures qualified to AWS D17.3/4 and NASA specifications
- Compliance
- CMMC compliant · ISO in progress
- Registered Supplier
- CAGE 119K1 · UEI U7HMV6HJNF14
- America Makes
- Member of the National Manufacturing Innovation Institute
Ready When You Are.
Tell us the metal and the size. You will hear back within 3 business days.
Collaborators
partners
