NO DIE
Days to Weeks, Not Months
No forging die or casting pattern to make, and no queue behind one.
Friction stir manufacturing · Youngstown, Ohio
Large Metal Structures, Built Without Melting
Why LeapFast
What Makes LeapFast Stand Out?
Bobbin Friction Stir Deposition (B-FSD):
- Exclusive license on NASA patent
- Unlocking the benefits of additive for massive metal structures
- Digital-twin-driven qualification and process monitoring
- No melting to achieve superior performance
- Runs on existing friction stir welding equipment, enabling agile manufacturing cells
STRONG
Forge Equivalent
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 hollow-form structures go up fast.
FLEXIBILITY
Optimal Designs Unlocked
Self-reacting process tool allows for low process loads and complex curved structures with variable thickness.
Our 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 intend to take that process off-world and use it to build moon bases.
Credentials
What Stands Behind the Claim
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
Send Us the Part That Is Holding Up Your Program.
A drawing, a STEP file, or a sketch and a size is enough. We reply within 3 business days, including when the answer is no.
Collaborators
partners
