The Ultrasonic Rapid Manufacturing process is a new non-thermal rapid prototyping technique for layered fabrication of metallic or multiple-material products. The process introduced in this paper employs ultrasonic welding and contour cutting of thin material foils. Its laboratory implementation, automation and integration, and parameter optimization are described first. Next, a numerical FEA simulation of the static and dynamic stress/strain field, based on experimental calibration of the friction coefficient between the welded surfaces, is established and found in agreement with laboratory strain data. Last, the technical advantages of the process, including fabrication of dense, full-strength functional solid metal parts, multiple-material composites, and active parts with embedded intelligent components and electronic, mechatronic, optic and fluidic structures, are examined in the manufacturing industry.

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