Fortius Metals CEO, Jeph Ruppert, sits down with Balerion Senior Associate, Aidan Daoussis, to discuss the rise of large-format metal additive manufacturing and next-generation alloys.
00:00 – 01:00 Welcome & introductions
Aidan opens the webinar and introduces Jeph Ruppert, CEO of Fortius Metals, framing the conversation around next-generation alloys, large-format metal additive manufacturing, and U.S. industrial resilience.
01:00 – 03:30 What Fortius Metals does
Jeph explains Fortius’s origins as a spin-out of Elementum 3D and introduces Reactive Additive Manufacturing (RAM), a grain-inoculation technology that enables high-strength alloys to be welded and additively manufactured without cracking.
03:30 – 06:30 Why high-performance aluminum is hard to manufacture
Discussion of why alloys like 7075 and 6061 are difficult or impossible to weld conventionally, how columnar grain growth causes hot cracking, and why this limits aerospace and defense manufacturing.
06:30 – 09:00 RAM-enabled weld wire and solid-state metallurgy
How Fortius produces specialized weld wire that modifies solidification behavior, enabling robotic welding with forged- or cast-like mechanical properties.
09:00 – 12:00 From welding to large-format additive manufacturing
The leap from weld wire to robotic, large-scale metal AM systems. Labor shortages in skilled welding (hundreds of thousands of unfilled roles) make automation inevitable.
12:00 – 15:00 Predictive simulation as the “secret sauce”
Jeph describes Fortius’s physics-based simulation stack: predicting heat flow, distortion, residual stress, and final geometry before a single weld is made—embedding PhD-level welding expertise into software.
15:00 – 18:00 Near-net-shape parts with forging-level properties
How Fortius reduces machining, material waste, and lead times by producing large, near-net-shape components that traditionally require forgings, castings, or complex assemblies.
18:00 – 21:00 Jeph Ruppert’s background and path to Fortius
Jeph walks through his career: molecular biology, economics, early medical 3D printing, work at 3D Systems, and how those experiences shaped his view of scalable, production-grade additive manufacturing.
21:00 – 24:00 Complementing casting and forging (not replacing them)
Fortius is positioned as an additive extension of traditional manufacturing—filling gaps where tooling, scale, or lead time make casting and forging impractical.
24:00 – 27:00 Defense, aerospace, and energy applications
Specific examples of large, complex parts in aerospace, defense, and energy systems that are bottlenecked by tooling delays, foreign sourcing, or labor constraints.
27:00 – 30:00 Qualification, certification, and repeatability
Why qualifying large AM metal parts is harder than small ones; Fortius’s approach to repeatability, process control, and meeting customer certification requirements.
30:00 – 33:00 Supply chain resilience and reshoring
Discussion of how technologies like Fortius reduce dependence on foreign foundries and forges, and why advanced manufacturing is now a strategic—not just economic—priority.
33:00 – 37:00 Rare materials, alloys, and strategic metals
Conversation on alloy supply chains, access to high-performance materials, and why metallurgy is becoming a geopolitical issue tied to national security.
37:00 – 41:00 Manufacturing scale vs. elegance
Jeph and Aidan discuss the difference between “cool demos” and scalable manufacturing systems. Emphasis on reliability, uptime, and throughput over novelty.
41:00 – 44:00 Founders, leadership, and execution risk
What separates successful industrial startups from failed ones: leadership discipline, customer alignment, patience with qualification cycles, and resisting over-hype.
44:00 – 47:00 The future factory
A vision of software-defined factories where welding, additive, machining, and inspection are integrated into closed-loop, automated production cells.
47:00 – 50:00 Investment thesis for advanced manufacturing
Why investors are returning to “hard tech” manufacturing, how Fortius fits into a broader industrial renaissance, and what success looks like over the next decade.
50:00 – 52:00 Closing reflections
Final thoughts from Jeph on Fortius’s roadmap, the urgency of rebuilding U.S. industrial capability, and why this moment feels like an inflection point.
