This startup’s super metals could soon be in military drones, luxury watches, and chef’s knives

In a groundbreaking shift reminiscent of ancient metalworking practices, a startup named Foundation Alloy is redefining how metals are combined. Instead of the traditional method of melting and mixing, the company utilizes a novel technique that involves smashing metal powder particles together. According to Jake Guglin, the co-founder and CEO of Foundation Alloy, this innovative approach allows for the creation of metal properties that were previously unattainable. While the startup has been providing its custom metals to various clients in small quantities, demand is soaring. "Our challenge lies in production capacity, not in finding customers," Guglin stated. Foundation Alloy has established partnerships with several sectors, including automotive, aerospace, semiconductor, and defense, as well as manufacturers of luxury watches and chef’s knives. Guglin emphasized the potential for significant cost savings and waste reduction in these industries. To ramp up production to several tons weekly by 2027, Foundation Alloy has secured $22 million in Series A funding, led by Voyager Ventures. Additional investors include Trust Ventures, Yamaha Motors, America’s Frontier Fund, and others, with Kanematsu Corporation set to distribute the startup's metals in Japan and Southeast Asia. The technology behind Foundation Alloy stems from over two decades of scientific research into metals at the nanometer level, spearheaded by Tim Rupert and Chris Schuh. Schuh, who co-founded firms like Desktop Metal, is well-versed in the startup ecosystem. Unlike conventional alloys that are created through melting, Foundation Alloy's unique milling process consumes significantly less energy and produces stronger, more versatile metals. Traditionally, alloying has faced challenges, particularly with metals that have vastly different melting points. This limitation has hindered the creation of alloys with potentially beneficial properties. Foundation Alloy's solid-state alloying technique allows for a superior molecular structure, addressing age-old trade-offs between heat resistance and mechanical strength. The startup’s initial offerings include tooling parts designed for the automotive, aerospace, and defense sectors, with particular focus on drone components. These components are essential for modern military applications, where production needs can far exceed traditional manufacturing capabilities. Guglin likened the alloying process to cooking, where the quality of the final product is determined not solely by the ingredients used but also by the method of preparation. "The quality of the output is influenced by the cooking technique," he explained, hinting at the transformative potential of their method. "We have discovered a new way to cook metals."