To extend current ultrasonic additive manufacturing (UAM) to advanced materials, higher speeds and larger parts, it was essential to greatly increase the process ultrasonic power. EWI, with Solidica™, several industry, agency and academic partners, and support of Ohio’s Wright Program, have developed a “Very High Power Ultrasonic Additive Manufacturing System” that greatly extends current technology. A key part was the design of a 9.0 kW “push-pull” ultrasonic system able to produce sound welds in materials such as Ti 6-4, 316SS, 1100 Cu and Al7075. The VHP system can fabricate parts of up to 1.5m x 1.5m x 0.6m, with process and software developments that enable forming contoured surfaces.