Explore how VulcanForms enables complex designs in metal manufacturing by integrating additive and subtractive processes
Through its focus on vertically integrated manufacturing, precision machining, and industrial automation, VulcanForms is setting a new standard for advanced metal manufacturing. With the goal of helping innovators create better performing parts while ensuring a secure and reliable US-based supply chain, the company provides advanced manufacturing capabilities that enable complex geometries, optimized performance, and material efficiency at scale. From lightweight structures to intricate components, VulcanForms’ digital production system removes traditional design constraints, transforming ideas into reality. Alex Fishman, Head of Marketing, joins Manufacturing Today for an informative discussion on the company’s operations and latest achievements.
“Born out of the Massachusetts Institute of Technology (MIT), VulcanForms was co-founded by John Hart and Martin Feldmann just over ten years ago.
Initially established at MIT with a vision to change how critical metal parts are produced at scale, we now leverage that innovation as a competitive advantage against traditional manufacturing techniques. In other words, we empower American companies to make the next generation of products while also building the factories that manufacture these components,” he begins.
These parts are essential to the development of advanced assemblies, making VulcanForms a crucial player in the American manufacturing landscape. “In terms of parts and services, we go beyond being a traditional supplier by offering end-to-end manufacturing. We set up long-term relationships and agreements, investing significant upfront work with qualification. Once we finalize that process, it is implemented in our factories, which then produce the required quantities for the duration of the contract. Our capabilities encompass everything from design for manufacturing to sourcing the powder needed for printing. We then utilize that powder to power our printers, followed by post-processing, including subtractive manufacturing, coatings, and finishing. Lastly, each part is serialized and undergoes extensive quality control to ensure that we have met all criteria set by our partners. We primarily work with medical and aerospace applications, producing components like hip cups, stators, and cooling components with intricate internal channels. Additionally, we are exploring various consumer applications that require specific surface roughness. Essentially, our technology can be applied anywhere, as long as the material is suited for our processes,” Alex explains.
VulcanForms’s comprehensive capabilities are supported by its two state-of-the-art manufacturing facilities in Massachusetts: VulcanOne and VulcanTwo. “Located in Devens, Massachusetts, V1 is our larger facility and the heart of the business. It currently houses all our additive manufacturing (AM) equipment, 3D printing cells, and secondary and tertiary equipment. Everything needed to run a job from start to finish is contained within this facility, and most of our corporate employees are based here as well. Meanwhile, V2 is situated in Newburyport, Massachusetts, and is a legacy business that has been operational for over 60 years and was originally known as Arwood Machine. We acquired this company a few years ago, primarily to give us an advantage in subtractive manufacturing. Inheriting a business with such extensive experience, know-how and tribal knowledge significantly helped amplify our end-to-end capabilities.
“I believe that V2 is a fascinating facility, as it is vastly different from V1. It operates more like a traditional manufacturing environment, featuring equipment like mills and lathes, which can be messier. In contrast, our V1 facility is a newer building where you can hear a pin drop, given that the printers do not make any noise at all. This represents a different manufacturing paradigm. When visitors open the doors to V1, they are often quite surprised, as they expect something more like our V2 facility in Newburyport, but the advanced equipment we use is not typical of traditional manufacturing,” Alex says.
Innovative equipment is an important area of investment for VulcanForms, as Alex points out. “A significant portion of our investments has gone into developing our own printing technology. We are currently at a highly stable system that was designed for many of the applications I mentioned earlier. For a long time, our focus was on engineering to ensure we produced world-class products, which in turn enabled us to manufacture world-class parts. But now, our emphasis has shifted toward scaling the business and enhancing the capabilities that truly make us an end-to-end manufacturer. As a result, we are making substantial investments in areas like powder sourcing, exploring whether to purchase powder from external suppliers or to produce it internally. These are critical considerations for our future investments.”
The enduring success of VulcanForms transcends its investments in technology and innovation. Indeed, it is also fueled by the company’s strong supply network built on productive and trustworthy partnerships, which plays a crucial role in ensuring quality. “We provide substantial upfront support to many of the companies we collaborate with, helping them develop solutions that will lead to their success, all at an affordable rate. This approach allows us to thrive while fostering a partnership that can grow over time. Often, we encourage them to transition to new techniques that could potentially save costs or improve designs. However, these changes come with significant risks and requires a lot of trust from our partners. Instead of seeking quick-turn projects, we aim to establish agreements lasting three, five, or even ten years, during which we can build out our capacity. We look for genuine, equitable partnerships where both companies invest considerable resources and funding to ensure mutual success. It is crucial that each time we acquire a new customer, we are prepared to act quickly by assessing whether we need more equipment or systems. Additionally, as these partnerships involve co-development, we engage with our partners to create solutions without jeopardizing their operations,” Alex ends.
VulcanForms is building the factories that will define the future of American metal manufacturing, fully integrated, digital, and at scale through relentless innovation and client support. By fostering long-term partnerships, the company empowers industries to achieve unprecedented performance and efficiency in production.