The United States once led the world in metal casting, but since its 1950s peak more than 70% of domestic foundries have shut down, and China and India now dominate global production. Fabri, founded by Steven Davis, Thomas Cole and Pieter Coulier, combines additive manufacturing, proprietary software, and vertical integration to build a new kind of foundry that aims to revive American metal casting.\n\nOperating from a 16,000‑sq‑ft plant in Billerica, Massachusetts, Fabri already supplies parts to Raytheon, Lockheed Martin, Sikorsky Aircraft and others, and is moving through qualification for critical aerospace and defense applications.\n\nTraditional investment casting is a multistep process: a hard steel tool is cut, wax patterns are injection‑molded into it, the wax pieces are assembled into a “tree,” the tree is dipped in a ceramic‑loaded slurry, coated with sand, dried, and the dip‑dry cycle is repeated seven or eight times to create a ceramic shell, which is then filled with molten metal to form the part.\n\nFabri starts with a CAD file. Its proprietary software, FoundryOS, automatically generates a pattern for each part, which is printed in resin using digital light processing (DLP) or stereolithography (SLA). The printed pattern is dipped in ceramic slurry to build the shell that will receive the molten metal. FoundryOS logs data from every step and applies machine‑learning models to continuously improve both the process and the final parts.\n\nTraditional tooling can exceed $1 million and take months to produce. Davis built the first printer prototype in his MIT fraternity basement with funding from the MIT Sandbox Innovation Fund; after subleasing space in Ashland, Massachusetts, Fabri began pouring metal within six months and later moved to Billerica. Today the company can go from design receipt to finished part in as little as a week, working with aluminum, copper alloys and stainless steel, and plans to start casting nickel super‑alloys in early 2027—materials currently subject to four‑year lead times.\n\nLabor shortages are a core bottleneck—foundry engineers are retiring at a 3‑to‑1 ratio. Fabri encodes this expertise into software, automating the entire workflow and dramatically reducing reliance on scarce skilled labor, while the flexibility of 3D printing lets the team iterate on designs within days.\n\nLooking ahead, Fabri will build a much larger facility in 2027 to produce bigger parts at higher volumes, supporting aviation, naval and munitions programs and strengthening the United States’ self‑sufficiency in critical metal‑casting supply chains.\n\nReview: Fabri’s integration of digital design, additive manufacturing, and AI‑driven process optimization transforms a historically costly and inflexible industry, offering a scalable path for revitalizing American manufacturing.