About Us

In 1984, Metal Fusion embarked on its journey by repairing aircraft engine parts in a modest garage near the UAL Maintenance Base at San Francisco International Airport. The business officially launched in 1985, setting up shop in a small industrial park in Belmont. By the end of that year, Metal Fusion had earned FAA Repair Station No. CG3R422L approval for TIG welding, dye penetrant inspection, and machining.

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The heart of Metal Fusion’s work centered around repairing a specific DC-10 engine part for Garrett Air Research, which later became Allied Signal and was eventually acquired by Honeywell. From 1984 to 1991, the company focused exclusively on this critical engine component, becoming the sole provider for repairs. Airlines operating DC-10s relied on Metal Fusion’s expertise, solidifying the company’s position as a trusted vendor.

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However, in 1991, an economic downturn hit, causing Metal Fusion to lose over half of its workload. Undeterred, the company had recently invested significantly in a building in Redwood City. To adapt, Metal Fusion expanded its services beyond aviation, venturing into industrial repair and the semiconductor industry. The team developed repair solutions for various aircraft parts, broadening their expertise.

Since 1995, Metal Fusion has split its efforts between aerospace, semiconductors, and industrial applications. Their 5000-square-foot concrete tilt-up building, established in 1990, has been a reliable hub for innovation. In 1988, they transitioned into the thermal spray business with the acquisition of a Metco 3M plasma spray system. Collaborating with a fuel cell development company in 2003, Metal Fusion expanded further.

By 2012, the company had invested in two Metco 9M plasma spray systems, complemented by Fanuc robotic capabilities. These systems allowed Metal Fusion to become a key supplier of thermal spray solutions for the fuel cell industry. Today, their clientele includes satellite manufacturers, VTOL (Vertical Takeoff and Landing) technology companies, and rocket engine manufacturers. They specialize in providing thermal barrier coatings for 3D-printed parts and also repair J85 turbine engine components and other high-value mechanical parts across diverse industries.

Metal Fusion’s journey from repairing DC-10 engine parts to pioneering thermal spray technology exemplifies their adaptability and commitment to excellence. 🚀✨