Case Study
The Pump Repair Business: A Case Study of Quick Turnaround Casting
by Rakesh “Rocky” Nalla, BIMAC Precision Castings
urgent, time-sensitive orders. Major pump manufacturers rely on BIMAC when their customers need to restore pumping systems in pipelines and processing
B
IMAC Precision Castings, an Ohio-based
investment casting foundry, is well-versed in handling
facilities. These situations
often involve small order quantities, unknown component requirements prior to disassembly, and an immediate need to resume operations. To meet these demands, BIMAC has
developed a proven, streamlined process for expediting casting production— without compromising
quality. The
components most commonly required are large impellers, diffusers, and housings. Critical, high-stress parts are found in pumping systems used across the water, oil and gas, chemical, and power generation industries. For operators of these systems, downtime is costly, and lead times on replacement parts are absolutely critical. In many cases, orders are awarded to the foundry that can quote and deliver the fastest turnaround from initial inquiry to shipping the finished casting. To remain a top choice in this competitive space, BIMAC has refined its internal workflows to reliably produce high- quality pump repair castings within accelerated timelines. We not only quote some of the shortest lead times in the industry – we consistently deliver on them.
In addition to speed and reliability, customers frequently tell us we offer some of the most competitive prices in the market. By maintaining efficiency throughout our operations and leveraging deep industry experience, we’re able to provide exceptional value, earning us the trust and repeat business of customers across the United States and beyond.
28 ❘ July 2025 ® Above: Pump impellor castings completed in short lead time at BIMAC. What follows is an overview
of BIMAC’s specialized process for expediting pump-repair castings. An approach that continues to distinguish us in the field.
Rapid Prototyping: the Key to Casting with Short Lead Times At BIMAC Precision Castings, two metalcasting processes are utilized to meet a broad range of part specifications: investment casting (lost-wax process) and ceramic mold casting (Shaw Process). For standard production, both processes rely on permanent tooling— typically fabricated from aluminum, stainless steel, or legacy wood-and- resin pattern materials. However, for time-sensitive pump repair components, the lead time required to fabricate permanent tooling is prohibitive. To address this, BIMAC leverages to produce
additive manufacturing
polymer patterns without the delay of traditional tooling. Upon receipt of a
digitized part file (typically in STEP format), BIMAC’s engineering team initiates a simulation workflow using Solid Cast software. This simulation models solidification behavior, gate and riser placement, and alloy flow to ensure dimensional accuracy and defect-free castings.
Once gating and shrinkage
allowances are optimized, a full-scale pattern is produced using a Voxeljet binder jetting system, employing printer polymethyl methacrylate (PMMA). This polymer exhibits favorable burnout characteristics for producing quality castings. The PMMA pattern dimensionally compensates for expected shrinkage of the cast alloy and is typically ready within three business days of customer file submission. Following pattern production, the component enters the ceramic shelling phase.
The pattern is successively
coated with refractory slurry and stucco to build a high-integrity ceramic mold. Shell build-up and curing are completed
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