Rapid Precision Castings - From File to Foundry in Days, Not Months

The Future of Casting is Digital

100% elimination of up-front tooling cost and lead time in

Achieve 100% elimination of up-front tooling costs and reduce lead time for

The only Digital Foundry that 3D prints ready-to-pour ceramic shells directly from your CAD file, so you can get precision metal castings in days instead of months, with zero tooling investment.

10x faster (first parts in 10 days vs. 52-80 weeks)

50% cost reduction

7 of 12 process steps eliminated

90% reduction in scrap/defects

Up to 90% energy savings (ARPA-E validated)

26+ patents across 6 countries

$16.55B TAM growing to $23B by 2030

$8M+ in past/current contract revenue

Rapid Precision Castings - From File to Foundry in Days, Not Months

The Future of Casting is Digital

100% elimination of up-front tooling cost and lead time in

The only Digital Foundry that 3D prints ready-to-pour ceramic shells directly from your CAD file, so you can get precision metal castings in days instead of months, with zero tooling investment.

10x faster (first parts in 10 days vs. 52-80 weeks)

50% cost reduction

7 of 12 process steps eliminated

90% reduction in scrap/defects

Up to 90% energy savings (ARPA-E validated)

26+ patents across 6 countries

$16.55B TAM growing to $23B by 2030

$8M+ in past/current contract revenue

Trusted By

AEROSPACE & MANUFACTURING LEADERS

Rob Meyerson

Former President, Blue Origin

Rapid Precision Casting’s digital foundry technology represents a major advancement in casting speed and cost efficiency.

Rob Meyerson

Former President, Blue Origin

Rapid Precision Casting’s digital foundry technology represents a major advancement in casting speed and cost efficiency.

Rob Meyerson

Former President, Blue Origin

Rapid Precision Casting’s digital foundry technology represents a major advancement in casting speed and cost efficiency.

Rob Meyerson

Former President, Blue Origin

Rapid Precision Casting’s digital foundry technology represents a major advancement in casting speed and cost efficiency.

Key Industries Served

Aerospace and Aviation

We manufacture turbine engine hot-section components, airfoils, and complex structural elements using single-crystal and directionally-solidified superalloys, supporting legacy fighter aircraft replacement parts with aerospace-grade quality standards.

Defense

Our ITAR-registered facility produces certified parts for USAF B-2 Spirit, A-10 Thunderbolt II, and C-5 Galaxy aircraft, plus hypersonic missile system castings for major defense contractors.

Space Exploration

We manufacture NASA Space Launch System RS-25 rocket engine components and space-qualified castings that withstand extreme operating conditions for aerospace propulsion systems.

Power Generation and Gas Turbines

We produce industrial gas turbine components, including hot gas path parts, blades, and housings that support hydrogen turbine applications and data center power infrastructure.

Medical and Healthcare

Our biocompatible casting capabilities include knee implants and patient-specific medical devices using cobalt chromium alloys that meet FDA requirements.

Vehicle Electrification

We deliver lightweight aluminum components and assemblies for electric vehicles, including battery housings, electric motor enclosures, and cooling system parts. Our cost-effective manufacturing process produces high-quality parts for power electronics and charging infrastructure, meeting the growing demand for precision casting in the EV industry.

Robotics and Drones

Our custom manufacturing services produce precision structural components for robotic systems and drone airframes, from actuator housings to sensor mounting brackets. We deliver lightweight, high-strength materials suitable for unmanned systems, giving manufacturers access to prototype and production volumes with rapid delivery.

Other Industries

Beyond aerospace applications, we serve automotive manufacturers with complex cast components from prototype to production, industrial fluid flow customers requiring closed impellers with intricate internal assemblies, and the energy and oil & gas industry with precision cast components built to withstand high-pressure environment conditions.

Proprietary Technology Showcase

LAMP™ Technology (Large Area Maskless Photopolymerization)

LAMP™ is our leading precision casting technology that produces investment casting molds directly from CAD files without tooling. This cost effective manufacturing process eliminates 7 of 12 traditional casting steps, removing 90% of waste sources and delivering approximately 33% lower cost—making it suitable for aerospace applications, prototype development, and large quantities at scale.

How LAMP Works (Step-by-Step)

Digital Input: Customer provides CAD model of desired part.

Digital Slicing: Software converts CAD into thousands of high-resolution bitmap images.

Slurry Preparation: Proprietary mixture of photosensitive binder resin and ceramic particles is prepared.

Layer Deposition: Ceramic slurry spread in 100-micron layers onto build platform.

UV Photopolymerization: Printer head projects patterned UV light onto ceramic suspension, selectively curing resin.

Layer-by-Layer Building: Process repeats using scanning maskless lithography until structure complete.

Binder Burnout: Cured photopolymer resin removed through thermal processing.

High-Temperature Sintering: Ceramic structure fired in furnace to produce fully dense article.

Ready-to-Pour Mold: Final ceramic shell with integrated cores ready for metal pouring.

DirectPour™ Investment Process

DirectPour™ is our end-to-end custom manufacturing service that leverages LAMP™ technology to deliver high-quality parts with rapid delivery.

Customers submit a CAD model, specify alloy (including aluminum and titanium), and volume demand. Rapid Precision Casting’s team of experts designs optimized ceramic molds with integrated cores. The shell is then 3D printed using LAMP, thermally processed, and poured with molten metal at our facilities – or delivered “ready to pour” to foundry customers and supply chain partners for traditional metal casting.

Process Flow

Customer submits CAD model and specifies alloy/quantity.

DDM engineers design optimized ceramic shell with integrated cores.

Shell 3D printed using LAMP technology.

Thermal processing (binder burnout + high-temp firing).

Monolithic shell poured at DDM or delivered "ready to pour" to foundry customers and partners.

Traditional investment casting metal pour.

Finished castings delivered to customer.

SLE™ Technology (Scanning Laser Epitaxy)

SLE™ is our metal additive manufacturing technology for high-performance superalloy components crucial to aerospace applications. This patented process enables manufacturers to restore damaged superalloy cast components through precision additive repair, delivering significant benefits over traditional methods, including cost-effective testing and access to production-ready services that extend component life under demanding environmental conditions.

How SLE Works

Gas-atomized, pre-alloyed superalloy powder spread on build platform.

High-power laser scans powder bed in controlled pattern.

Laser selectively melts powder, creating melt pool bonding to substrate.

Through controlled thermal conditions, material solidifies epitaxially.

Process parameters control resulting microstructure (EQ, DS, or SX).

How It Works

01.

Send Casting Model

02.

Specify Alloy and Quantity

03.

Get a Quote and Issue a PO

04.

Receive Your Parts

Speed & Cost Advantages: From CAD to Cast Metal in Days, Not Months, Without a Single Tool or Die

10x Faster Production

First parts arrive in 10 days compared to 52-80 weeks with traditional investment casting. This dramatic acceleration enables rapid prototyping, urgent spare parts replacement, and compressed development cycles. Our streamlined process eliminates tooling design delays and manufacturing bottlenecks that plague conventional foundries.

Zero Tooling Investment

Complete elimination of upfront tooling costs removes the largest barrier to precision casting projects. Traditional foundries require $50K-$200K+ investments before production begins, while our digital process starts immediately from CAD files. Design changes cost nothing, encouraging optimization and innovation throughout development.

50% Cost Reduction

By removing 7 of 12 traditional process steps, we cut manufacturing costs in half while improving quality. The integrated approach eliminates separate core manufacturing, wax pattern creation, and multiple coating operations. Third-party validation confirms 26+ patents protect this competitive advantage across six countries.