outside shop, you don’t have that control. How the foam is fused is just as important as the coating to prevent porosity and other defects.” Another key to technical


proficiency is employee abil- ity, according to Lisa Bryant, human resources manager. “We have developed an


internal certification program and ensure everyone is quickly trained and certified at their operation,” she said. “From there, employees show their own initiative in going after higher level certifications. Turnover rates among full- time employees are almost nonexistent. We don’t lose people to other local employers, generally speaking.”


Where It’s Going Mercury Marine is BRP Spruce


Pine’s primary competitor for out- board engines. But the company keeps its competitor close. “From a sales perspective, we


are extremely competitive for every sale,” Campbell said. “But from an operations perspective, we have a very cordial relationship.” Tat’s because Mercury Marine and


BRP are one of only a handful of lost foam operations in the country. (GM operates the largest operation of its kind in Saginaw, Mich., and another dozen or so job shops sprinkle the country.) With such a small commu- nity, technology share is widespread. Tat’s a benefit, because develop- ing its existing technology and newer techniques will be critical in BRP’s plan to grow its commercial business. In 2011, the company estimated 48% of its tonnage shipped was captive recreational parts. As late as 2004, the plant was 100% captive. “We want to become even more


diversified in the future to protect our business during economic downturns,” Campbell said. Te low hanging fruit will be expanding markets the company is already in. Campbell believes the diesel engine market will continue to rely on aluminum conversions as light-weighting becomes increasingly


February 2012 MODERN CASTING | 27


prototyping method that involves machining of foam patterns. “It’s helped make people


come around, including the internal BRP design shops,” Campbell said. “[It] is a value service to lure customers and entice them to talk to us. It has paid huge dividends.” One of the challenges of


BRP Spruce Pine considers in-house foam pattern production and coating critical to its success.


important and engineers recognize that much of the iron they were using was over-specified. Te company expects more far


reaching expansion to come with sev- eral newer process technologies. It’s already found success with a


any casting process is the inability to cast in extremely small passageways. “We realized you could make a small passage if you [could cast in a] steel tube insert or line of some sort,”


Kerlin said. “A company reached out to us to do some research and devel- opment, and it’s now developing into a relationship. We are molding into foam over 9 ft. of stainless steel tube, which is coiled to form a cooling passage, then casting an


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