Fabrication Services
Prototype Casting
SLA print-to-rapid-cast with small-scale vacuum induction melting for advanced alloys. Sand casting available for simpler geometries and faster turnaround.
Availability Note: Some advanced services are limited while equipment recovery continues after flood damage. If you have a deadline, include it in your request and we will tell you what is realistic.
Flagship Offering
Integrated Casting Workflow
SLA-printed patterns to rapid cast, through final machining and documented inspection — all under one roof. Heat treatment can be coordinated as a managed service. Fewer vendor handoffs, faster iteration.
1
CAD & Engineering Review
2
SLA Pattern Print
3
Casting
Sand or rapid investment
4
Heat Treat
Managed service, when required
5
CNC Machining to Print
6
Dimensional Inspection
Workflow steps vary by alloy and geometry.
What This Solves
- •Reduces multi-vendor coordination
- •Maintains traceability across casting and machining
- •Supports dimensional refinement after shrink
- •Accelerates prototype iteration cycles
Final Deliverables
- •Cast part
- •Heat treated (if required)
- •Machined critical surfaces to print
- •Basic dimensional inspection report
- •Process summary documentation
Managed Heat Treatment
When alloy systems require heat treatment, we coordinate with qualified partners and manage the process as part of the casting workflow. Heat treatment specifications are reviewed during engineering intake.
- •Alloy-specific heat treat selection
- •Managed vendor coordination
- •Linked documentation
- •Turnaround integrated into overall schedule
Heat treatment is performed by external partners. Availability and lead time vary by alloy.
Typical Lead Time: 4–10 weeks depending on alloy, machining scope, and heat treatment requirements.
Designed for prototype and pre-production validation. Not intended for production volumes.
Casting Pathways
Standard Process
Sand Cast Prototypes
Sand casting for larger, simpler, or more forgiving geometries. Faster turnaround and lower cost when fine internal detail or advanced alloy control is not required. 3D printed plugs enable an expedited option on qualifying parts.
Expedited 24-Hour Option (When Eligible)
- •Simple, open geometry
- •No complex cores
- •In-house 3D printed plug
- •Readily available alloy
- •Engineering approval required
Not all projects qualify. Engineering review required.
Best For:
- •Structural brackets and housings
- •Non-critical geometry validation
- •Cost-sensitive prototypes
- •Aluminum and common ferrous alloys
Typical Lead Time: 2–4 weeks standard · expedited option available for qualifying parts
Rapid Investment
SLA Print-to-Cast
SLA-printed patterns fed directly into a rapid investment casting workflow. Enables tighter dimensional control and more complex geometry than sand casting, with quicker iteration than traditional tooled investment casting.
Best For:
- •Complex geometries
- •Thin sections and fine features
- •Advanced alloys requiring VIM
- •Pre-production validation
Typical Lead Time: 3–8 weeks depending on alloy and geometry
Small-Scale VIM Capability
Our small-scale Vacuum Induction Melter enables controlled atmosphere melting of reactive and high-performance alloys — supporting titanium and nickel-based systems where oxidation control and melt chemistry stability are critical.
Controlled melt atmosphere
Small-batch volumes
Documented melt cycle
Resin batch → mold batch → melt batch traceability
Advanced Capability
Advanced Alloy Support (SLA Print-to-Cast + VIM)
Titanium Alloys
- •Prototype-scale melt quantities
- •Controlled melt environment
- •Engineering review required
- •Geometry validation and early hardware
Nickel-Based Superalloys
- •Inconel-class and Mar-series materials
- •Small-batch VIM capability
- •High-temperature prototype components
Maraging & Specialty Steels
- •Controlled chemistry melts (prototype scale)
- •Tooling, structural R&D, high-strength applications
Cobalt & High-Performance Copper Alloys
- •R&D quantities
- •Complex geometry support
- •Application-specific review required
All advanced alloys subject to engineering review and melt capacity constraints.
What You Receive
- •Cast part(s)
- •Basic dimensional inspection
- •Melt record summary (when applicable)
- •Process notes to support iteration
What We Need From You
- •CAD files (STEP preferred)
- •Material requirements and alloy preferences
- •Critical dimensions and tolerances
- •Quantity and timeline
- •Application context
In Development
Direct-Print Ceramic Mold Casting
We are developing a direct-print ceramic mold pathway using high solid-loading resin systems. This will enable complex internal features and tighter dimensional control compared to sand casting — without traditional wax tooling. Not yet offered as a production service. Updates will be posted here as the process matures.
Scope & Review Notice
Prototype-scale capability only. Not all geometries or alloys are accepted. Reactive alloys, thin sections, or critical-load components require engineering consultation prior to scheduling.
Ready to Cast?
Submit your CAD files and requirements for engineering review. We'll assess castability, recommend the appropriate pathway, and provide a scoped proposal.