LeapFast Leverages Funding to Increase Defense & Aerospace Readiness
Youngstown, OH — LeapFast Manufacturing, Inc., has been awarded $75K through the state funded YBI ENGINE Tech Incubator, Youngstown Innovation Hub for Aerospace & Defense (managed by the National Center for Defense Manufacturing and Machining), and the federally funded YBI Rising Tides Initiative. This funding will enable LeapFast to establish a development lab, expanding its capacity for contract manufacturing, advancing innovative research and development (R&D), and strengthening its participation in Small Business Innovation Research and Small Business Technology Transfer (SBIR/STTR) programs.
LeapFast, an advanced manufacturing startup revolutionizing aerospace and defense production, leverages friction stir welding (FSW), additive manufacturing, and Metalworks Digital Twin (MDT) technology to deliver stronger, more affordable components with faster turnaround times.
LeapFast’s proprietary process, Bobbin Friction Stir Deposition (B-FSD), was invented by co-founder Zach Courtright during his tenure at NASA and has since been licensed to the company for commercial application across defense, aerospace, and industrial sectors.
Based in Youngstown, OH, and operating out of YBI, LeapFast’s specialty lies in its FSW capabilities, which enables the production of high-strength, distortion-free aluminum assemblies for companies lacking in-house FSW equipment/capacity or aerospace manufacturing expertise.
Side-by-side comparison of a unique geometry rocket stage manufactured with B-FSD and its digital twin representation, showcasing the design and manufacturing flexibility enabled by the process.
The grant funding is instrumental in advancing LeapFast’s mission and directly supports the Department of War’s (DoW) priorities by accelerating the transition from R&D to field capability. By growing its infrastructure and technical capacity, LeapFast is positioned to scale its impact, strengthen domestic manufacturing, and support next-generation defense and aerospace systems.
Additionally, the funds will expand the company’s capabilities in friction stir deposition, welding, and extrusion. Through partnerships with BOND Technologies and Brigham Young University, LeapFast has already acquired a development machine to accelerate processes, prototyping, and production readiness across these capabilities. Moreover, membership in the Center for Friction Stir Processing (CFSP) will allow LeapFast to influence technology development, identify strategic partnerships, and access experts and facilities. Collectively, these investments are expected to drive significant growth, with the company projecting up to six new local jobs by the end of 2026, spanning technical, engineering, and business management roles.
“LeapFast Manufacturing is driving large metal additive manufacturing from innovation to full-scale production,” said Zach Courtright, LeapFast CEO. “With the endless support of YBI and the Youngstown Innovation Hub, our co-founder, Kranthi Balusu and I have moved across the country to converge on downtown Youngstown. YBI provides us with facility space, matching grant funds, and plenty of sweat with no more than a commitment to create economic growth in the greater Youngstown region.”
The startup’s success underscores the long-term impact of the Youngstown Innovation Hub grant, showcasing how strategic funding can drive defense manufacturers, foster business growth, and enhance national manufacturing competitiveness.
