2013 Metalcaster ProsPectus


BRP – Lost Foam Casting Technology BRP sees the world as a giant playground


BRP Spruce Pine is a world class producer of complex aluminum castings utilizing the Lost Foam process.


Metal 356 Aluminum


Process Lost Foam


where our job is to provide powersports enthusiasts with the means to experience something unique. Our Sea-Doo, Ski-Doo, Can-Am and Evinrude products are known throughout the world. What isn’t as widely known is that BRP operates a lost foam aluminum foundry in Spruce Pine, NC. This is a complete lost foam facility, fully integrating all the process steps not usually found under one roof: from bead expansion to a fully heat treated, pressure tested, and machined component. This allows optimization of each process step to achieve maximum quality levels and eliminates unnecessary logistics issues. The facility is ISO 9001 certified. We also offer optional value added services such as impregnation, corrosion resistant treat- ments, epoxy painting, and component assembly—all from one location. The foundry was originally built as a captive facility to produce complex alumi- num marine castings for Evinrude outboard engines. If it is a 30 - 300 HP Evinrude engine, the blocks, the cylinder heads and the major exhaust system components were all produced here. In 2006, we started producing castings for external customers as well. Today, nearly half of the products we manufacture are for external custom- ers. What once was only a captive facility dedicated to its own products now serves many external customers with applications in the following industries:


• Automotive & Diesel Truck • Rail Car Braking Systems • Road Construction • Alternative Energy


Internal Core Example


The lost foam process provides many advantages over traditional casting methods. These advantages are not fully appreciated and certainly are not fully exploited today in the industry. Almost any casting design can be produced in lost foam; but designs with especially complex internal core geometries or the opportunity to consolidate several components into a single casting are natural fits for this process. Our focus is to attract opportunities where we can collaborate with product and application engineers to fully leverage these capabilities and maximize the entire value stream. We look into the future to refine and further develop the capabilities of the lost foam process not only through research and education, but through challenging and innovative casting opportunities.


BRP Spruce Pine 1211 Greenwood Rd.,


Spruce Pine, NC 28777 Tel: 828-766-1140


www.brp.com 36 METAL CASTING DESIGN & PURCHASING / 2013 Metalcaster Prospectus Spruce Pine – Lost Foam


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