Inside ICI


The IMPACT of Collaboration: Advancing Investment Casting through Additive Manufacturing by Merrin Muxlow


“Investment casting is at an


inflection point. If we do not continuously innovate and educate, we


stagnate. The integration of


Additive Manufacturing tools into all aspects of our processes isn’t just an improvement—it’s a necessity.” – Paul Finelt,


Concurrent Resources LLC T


wo years ago, the U.S. Department of Defense (DoD) sounded the alarm: the domestic casting and forging supply chain is a critical vulnerability, with delays that threaten our national security. This is not a hypothetical risk—this is a stark reality. Since 2000, a critical number of U.S. foundries have shuttered, leaving the nation’s defense industrial base struggling to keep up. Domestic foundries, the backbone of the US Organic Industrial Base, are stretched thin and forced to prioritize high-volume commercial contracts. This often leaves DoD projects facing unsustainable lead times and skyrocketing costs. The result? Mission-critical defense components delayed.


Recognizing these challenges,


industry leaders, government stakeholders, and technical experts convened at the


America Makes


Visioning Workshop in 2023 in Milwaukee to define the current state of casting and forging, identify future opportunities, and develop a roadmap for integrating Additive Manufacturing (AM) into traditional workflows. The key barriers to ramping up foundry production for the DoD won’t be a surprise to anyone in our industry— workforce shortages, long qualification processes, and the lack of AM material characterization were all cited as key barriers.


assessments, discussions,


Through expert interviews, and


the workshop 8 ❘ February 2025 ®


collaborative gave


all


stakeholders the opportunity to propose targeted initiatives that addressed these challenges.


America Makes and the National


Center for Defense Manufacturing and Machining (NCDMM) then released a call for the first of IMPACT (Improvements in Manufacturing Productivity via Additive Capabilities and Techno-Economic Analysis) projects in June of 2023. The projects’ total funding of $11.7M came from the Office of the Under Secretary of Defense, Research and Engineering Manufacturing Technology Office (OSD(R&E)) and the Air Force Research Laboratory (AFRL).


After a competitive selection process that demanded several rigorous proposals, the ICI was awarded funding under Topic 2 of the IMPACT Project Call: maturing AM ceramic technology and promoting its adoption for rapid, low-volume production of investment castings for defense applications. The IMPACT I project aimed to addresses the following issues:


• Streamlining Lead Times: AM can eliminate or reduce the time needed for steps like tool making, wax pattern injection, dipping and mold setup, enabling faster turnaround for critical components.


• Reducing Costs: By consolidating processes and improving material utilization, AM can significantly lower production costs while improving product quality.


• Enhancing Scalability: AM’s digital nature allows for rapid iteration and adaptation to meet evolving design and supply chain customer demand requirements.


The project’s focus on achieving


Technology Readiness Level (TRL) and Manufacturing Readiness Level (MRL) 7 ensures that new findings and processes are not only viable in laboratory settings, but ready for operational deployment at the conclusion of the project in 2025.


Continued on pg 10


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