Rapid Precision Castings

From CAD to Cast Metal in Days, Not Months Without a Single Tool or Die

Defense

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 days vs. 52-80 weeks traditionally)

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

Keith Weidman

CEO, Form Technologies

The Signicast and DDM partnership allows us to better serve the defense and aerospace industries. Rapid prototyping and additive manufacturing capabilities assist in achieving fully functional parts at a fraction of conventional cost and lead-time.

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Marc Riquelme

President, Signicast and OptiMIM

I write this note to recommend DDM systems products and processes. Signicast has been working with Suman Das for more than a year on developing several new products using the LAMP process and ceramic 3D printing. We recently signed a partnership with DDM to further expand our additive manufacturing capability and offering. The partnership between Signicast and DDM is evidence of the exciting advancement in precision casting technologies and will open up new design opportunities for our customers. Over time Signicast expects to transition this technology to full scale production in addition to prototyping.

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Cliff Fisher

COO, Seacast

Suman Das and his DDM team are developing technology that is industry changing! The forward thinking approach to a centuries old process in the investment casting world is the number one reason why partnering with Suman & DDM is an easy decision. I first was introduced to Suman many years ago and to see this relentless "bull-dog" approach to never giving up on the development of this process is what makes him stand out versus many others that have tried.

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Brett Lyons

Principal Technical Program Manager, Amazon

Suman Das has the depth of experience and breadth of knowledge required to make a step change contribution to additive manufacturing. Other companies, both large and small, have failed to consider the technical and economic implication of their additive based ceramic casting technology, but Suman's rigorous and thoughtful approach sets DDM apart.

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Rob Meyerson

Founder and CEO, Delalune Space

Suman has developed a revolutionary product that will shorten delivery times of critical parts from years to months. He is truly a disrupter in the field.

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Diego Tamburini

Principal Industry Lead, Cloud for Manufacturing at Microsoft

DDM offers an innovative model of what I would call "casting-as-a-service" on the cloud by allowing customers to just provide the CAD model of their parts and let DDM take care of the design, manufacture, and storage of the cast. They also use 3D-printing to print the ceramic shell of the cast, which introduces considerable efficiencies both from the material utilization and time perspectives.

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Thomas Pang

CEO, Additive Japan Corp

Suman is excellent in technology and second to none in his energy and drive to get things done. He worked on a materials innovation project with me in the past and I saw in him a superior ability to strategizing his approaches and overcoming challenges to reach the ultimate target.

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Kedar Murthy

Chief Commercial Officer, Boston Materials

Suman and team have developed break thru technology to disrupt the investment casting industry. Exceptionally talented founder with great vision grounded in facts.

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Derek Franklin

GM, Aerotec Alloys Foundry

Implementing DDM's technology will allow me to shut down the lights in half of my foundry.

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Prith Harasgama

President, Crosstown Power GmbH

Suman's and his team have established a revolutionary manufacturing process which has the potential to reduce lead times & costs and raise the quality of industrial cast parts. This will enable truly innovative ideas to be realised and rapidly launch new products into the market for many of DDM's clients.

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Shoumen Datta

Research Affiliate, MIT

Dr Suman Das co-discovered the field of 3D printing as a part of his PhD thesis, co-created the concept of cyber-manufacturing and a co-contributor to economic growth through innovations at DDM.

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Alan Amling

CEO at Thrive and Advance LLC

Suman and the team at DDM are delivering on the promise of AM by focusing on what can be done today vs what might be done in the future. The LAMP technology allows complex castings to be manufactured in a short time frame for less cost. This focus is what separates the doers at DDM from the dreamers.

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Jon Schaeffer

Senior Manager, Advanced Materials and Processes Engineering, GE

Suman and the DDM team have created a technology that is hard to replicate even with the advent of so many 3D printing businesses and modalities. GE is proud to work with DDM on several high technology castings for our Power business.

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John McIntyre

Director, CIBER at Georgia Tech

Suman Das is the perfect and unique combination of a world class researcher, a top professor able to communicate his material to a diverse audience of skilled individuals , and grasping and mastering the process of converting invention and innovation into commercial potential with multiple applications in various fields. Having known him for a long while, I have seen him handle the full range of complex and multiple tasks that characterize the life of the successful high tech entrepreneurial leader.

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Key Industries Served

Aviation

We manufacture turbine engine hot-section components, airfoils, and structural elements using single-crystal and directionally-solidified superalloys for legacy aircraft and aerospace-grade applications.

Aerospace and 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 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 for electric vehicles, including battery housings, motor enclosures, and cooling system parts for power electronics and charging infrastructure.

Robotics and Drones

We produce precision structural components for robotic systems and drone airframes, from actuator housings to sensor brackets, in both prototype and production volumes.

Other Industries

We serve automotive, industrial fluid flow, and energy sectors with complex cast components from closed impellers to high-pressure parts, from prototype to production.

The Future of Casting is Digital

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 & Specs

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 days — not months — 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.

Featured Articles

Insights on digital manufacturing, aerospace casting, and breakthrough technologies.

The Accountability Paradox and Why Pentagon Acquisition Reform Depends on Empowering Program Managers

Four senior Pentagon officials just declared that acquisition is now a warfighting function. Not a support...

The Navy Just Proved Something Nobody Wanted to Admit About Defense Manufacturing

I’ve been watching the Navy’s 3D printing experiments with the kind of attention you reserve...

The Gas Turbine Gridlock and Why the Next Decade Will Test Every Assumption About Power Infrastructure

The gas turbine industry just hit a wall it didn’t see coming. After years of declining orders...

The Metal Behind the Missiles. Why Investment Casting Shapes Defense Dominance

I’ve spent years watching defense contractors announce record backlogs and production ramps. The...

Epitaxial Matching Explained: Why Crystal Structure Matters in Superalloy Repair

Interactive visualization of the gamma (γ) matrix and gamma-prime (γ’) precipitate phases found...

Contact Us Today

Get in Touch

Visit our contact us page

Email

support@rapidprecisioncastings.com

Phone

470-225-6987

Address

1876 Defoor Ave NW, Suite 3, Atlanta, GA 30318, USA

Precision Casting FAQ

What is the meaning of precision casting?

Precision casting is a metal forming method that creates complex components by pouring molten metal into engineered molds, producing parts with exceptional dimensional accuracy and surface finish. This process offers significant advantages over sheet metal fabrication or CNC machining when manufacturing intricate geometries, internal passages, and thin-walled structures that would be virtually impossible to produce through subtractive methods. The ability to cast near-net-shape parts reduces material waste and machining requirements, making it a cost-effective solution for industries around the world that require tight tolerances.

What are the four types of casting?

The four primary casting methods include investment casting (lost-wax), sand casting, die casting, and centrifugal casting—each serving different applications based on volume, materials, and complexity requirements. Investment casting delivers superior precision and surface quality suitable for aerospace and medical components, sand casting handles large quantities at inexpensive tooling costs, die casting enables high-volume production of aluminum and zinc parts, and centrifugal casting excels at creating cylindrical shapes like pipes and rings.

What is an investment casting?

Investment casting is a centuries-old manufacturing method where a ceramic shell mold is built around a sacrificial pattern, then molten metal fills the cavity to create components with intricate detail and minimal finishing requirements. Traditional approaches require significant tooling investment and 52-80 week lead times, but Rapid Precision Casting's DirectPour™ innovation bypasses these limitations by 3D printing ready-to-pour ceramic shells directly from CAD models—a contrast that delivers parts in days rather than months.

What company offers precision casting in the United States?

Rapid Precision Casting is a leading American manufacturer headquartered in Atlanta, Georgia, offering job shop flexibility combined with production-scale capacity through their revolutionary Digital Foundry™ approach. Our ITAR-registered facility takes responsibility for serving defense, aerospace, and commercial customers—including partnerships with GE Vernova, Northrop Grumman, Rocketdyne, SpaceX, and the U.S. Air Force—while supporting supply chain reshoring initiatives critical to the future of domestic manufacturing. With the rise of demand for rapid prototyping and limited-run production, they provide internet-accessible quoting and services that link design teams directly to casting expertise. Call today at 470-225-6987 or contact us.