Ultrasonic consolidation, also known as ultrasonic additive manufacturing, is a layer-upon-layer process in which a 3D object is fabricated by joining metal foils using ultrasonic bonding, followed by shaping using a milling machine. Ultrasonic bonding between foils is accomplished with the help of a solid metallic probe called a sonotrode that is pressed onto these foils. After pressing, the sonotrode is given ultrasonic energy, causing it to vibrate with a certain amplitude and frequency across foils. A forced and vibrating sonotrode is enough to join foils. Its vibration smoothens the interface between two foils, destroys the oxide layer of the interface, and exposes the clean surface of one foil to that of another foil, causing plastic flow at the interface—these results in the creation of a metallurgical bond between two foils.