From CAD to Cast Metal in Days, Not Months — Zero Tooling Investment | ITAR Registered | Made in USA | Capability Statement
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Casting Grade Alloys |
Compatible Materials

Our Digital Foundry™ produces precision metal castings across hundreds of standard casting grade alloys — from air-melt aluminum, steel and nickel alloys to vacuum-melt nickel superalloys and medical-grade cobalt chrome — all without a single tool or die. Using our patented LAMP™ ceramic 3D printing technology and DirectPour™ process, we deliver production-grade cast parts directly from your CAD file in as little as 10 days. Every casting material we pour meets ASTM standards and Investment Casting Institute stated ranges, ensuring repeatable dimensional accuracy, surface finish and mechanical integrity across every project.

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Call Us: 470-225-6987

Benefits of DirectPour™ Process with Casting Grade Alloys

Accelerated Production Timelines

Traditional investment casting consumes multiple weeks to months in tooling alone. Our DirectPour™ process eliminates that bottleneck, delivering first castings in as little as 10 days:

1.
No tooling delays between the CAD file and the finished metal.
2.
Full alloy range available for single parts or production runs.
3.
10-day first-article delivery across air-melt and vacuum-melt alloys.

Zero Tooling Investment

Traditional casting demands $50K–$200K+ in upfront tooling before a single part is produced. Unlike traditional lost-wax casting, DirectPour™ goes straight from CAD to a ready-to-pour ceramic shell — no wax injection, no die fabrication, no wax patterns:

1.
No core tooling, wax tooling, or die fabrication required.
2.
No tooling lead time.
3.
7 of 12 traditional process steps removed from the workflow.
4.
No wax patterns and pattern tree assembly.
5.
No core assembly.

Superior Quality and Precision

Our LAMP™ technology delivers precision specs that reduce defects before a single drop of metal is poured. Every casting is third-party qualified to ASTM standards and Investment Casting Institute stated ranges:

1.
15-micron printing resolution with ±2 micron XYZ positioning accuracy.
2.
Tighter-tolerances in as-cast dimensions.
3.
4 microns RMS as-cast surface finish.
4.
90% of known scrap sources eliminated by removing 7 of 12 traditional steps.

Signs Your Project Needs Advanced Casting Alloys

Some casting requirements outgrow what conventional foundries can support. If any of the following describe your project, our ceramic 3D printing platform was built for it:

1.
Complex internal geometries requiring integrated cores without assembly.
2.
High-temperature applications demanding superalloy performance.
3.
Rapid prototyping in production-grade materials.
4.
Legacy part replacement with obsolete tooling.
5.
Design iterations requiring multiple material evaluations.
6.
Aerospace, defense, or medical applications with strict specifications.

Our engineering team provides direct technical consultation — reach out today to assess your alloy requirements.

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Alloy Capabilities

We produce metal castings in alloys spanning both ferrous and non-ferrous families, compatible with air-melt and vacuum-melt foundry processes. The core material categories below represent our most frequently specified casting grade alloys across aerospace, defense, space, medical, and industrial applications.

Stainless Steel Alloys (304, 316, 17-4 PH, 15-5 PH)

We cast the full spectrum of corrosion-resistant stainless grades — from standard 304 and 316 to precipitation-hardening 17-4 PH and 15-5 PH. Alloys such as 316 stainless steel are widely used in castings for the industrial and medical sectors due to their durability and biocompatibility. Each grade is available through our DirectPour™ process with no tooling required:

  • 304 and 316 for general corrosion resistance and fluid handling.
  • 17-4 PH and 15-5 PH for high tensile strength after heat treatment.
  • CF3M (cast SS316 equivalent) for maximum corrosion integrity.

All grades meet ASTM standards and are suited for aerospace brackets, medical hardware, and industrial structural components.

Aluminum Alloys (A356, A357)

For aerospace and defense aluminum castings, A356 and A357 are the benchmark alloys — lightweight, corrosion-resistant, and favored for structural flight hardware. We produce castings in both grades using our DirectPour™ process with no tooling required:

  • A356 for various aerospace components with proven AMS 2175 Class 1 Grade A radiographic results.
  • A357 for higher ultimate tensile strength and heat-treatable structural applications.
  • Both grades available in air-melt configurations.

Nickel Superalloys (Inconel 625)

Our castings in high-strength nickel superalloys cover the full spectrum of high-temperature requirements. We cast a broad superalloy library in both air-melt and vacuum-melt configurations:

  • Air-melt IN 625.
  • Vacuum-melt Equiaxed (EQ) superalloys including IN 625, IN 718, IN 713LC, MAR-M247, and IN100.
  • Vacuum-melt Directionally-solidified (DS) superalloys including René 80, René 141, René 142.
  • Vacuum-melt Single-crystal superalloys including CMSX-4 and René N5.

Cobalt Alloys (ASTM F75)

Cobalt alloys are an indispensable choice for applications demanding durability under extreme conditions, such as gas turbines, medical implants, and aerospace components. We cast Cobalt Chromium Molybdenum to ASTM F75 equivalent specifications using our DirectPour™ process with no tooling required:

  • Orthopedic implants and surgical instruments in production-equivalent ASTM F75 alloy.
  • Medical device prototypes with high-resolution as-cast features — no wax pattern or cores required.
  • Same alloy used in production implants, enabling true design validation before tooling.

Tool Steel (S7)

S7 is an air-hardening, shock-resistant tool steel well suited for industrial tooling, dies, and structural components demanding high impact toughness. DirectPour™ delivers cast-near-net-shape S7 components with no tooling lead time required:

  • S7 for industrial dies and fixtures requiring hardness and impact toughness.
  • Post-cast heat treatment to achieve wear-grade hardness for demanding applications.
  • 4140 steel for applications requiring toughness, fatigue resistance, and moderate hardness.

Our Casting Process

Image of CAD modeling on a computer (showing the software).
01

CAD Model Analysis, Casting Simulation and Shell Mold Optimization

Every project begins with a detailed engineering review of your CAD model — where most casting quality decisions are made before a single layer is printed:

1.
Geometry evaluation for casting compatibility and integrated core opportunities.
2.
Casting simulations including thermal and flow modeling to optimize gating and riser placement for the casting and selected alloy.
3.
Design-for-casting feedback to reduce cost and lead time.
4.
Optimized shell mold design with integrated cores.
Submit Your CAD Model
Image of LAMP™ technology 3D printer.
02

LAMP™ Technology Ceramic Shell Production

Our LAMP™ (Large Area Maskless Photopolymerization) process cures our proprietary ceramic slurry layer-by-layer using 4.1 million UV beams — producing a ready-to-pour shell with all internal cores integrated in a single printed structure:

1.
15-micron resolution with pixel density up to 9,700 pixels/mm².
2.
100-micron layer thickness and 600 × 600 × 600mm build volume.
3.
Shell firing involving binder burnout and high-temperature sintering.

The result is a dimensionally precise, pour-ready ceramic shell mold — no wax patterns required.

Learn About LAMP™ Process
Image of metal pouring casting.
03

Metal Pouring and Finishing

The completed ceramic shell is poured with metal at our Atlanta facility or shipped as a ready-to-pour shell to your foundry or a qualified partner:

1.
Air-melt and vacuum-melt environments are supported across all alloy families.
2.
Radiographic examination and final inspection to customer-specified standards.
3.
Delivery to ASTM and Investment Casting Institute dimensional tolerances.
Review Quality Standards

Casting Grade Alloy Investment and Pricing

No upfront tooling charges — pricing reflects engineering, materials, and part production only. Key cost factors include:

Zero tooling investment eliminates $50K–$200K+ in traditional upfront costs.

Per-part pricing scales with alloy type, volume, and complexity.

Contact us for a project-specific quote with a detailed cost breakdown.

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Why Choose Rapid Precision Castings for Casting Grade Alloys?

Proven Aerospace and Defense Experience

Our LAMP™ technology originated from a 2006 DARPA call for Disruptive Manufacturing Technologies. Aerospace and Defense programs define our process:

1.
ITAR registered.
2.
Founded on US Department of Defense-grade precision casting requirements from day one.
3.
Castings produced for the US Air Force A-10 Thunderbolt II, USAF B-2 Spirit, and C-5 Galaxy aircraft.

Advanced Technology Leadership

Our IP portfolio and validated program results set a standard conventional foundries cannot match:

1.
26+ patents across six countries with an exclusive LAMP™ technology license from Georgia Tech.
2.
Decade-long collaboration with GE Vernova including a $3.3M ARPA-E program.
3.
Awarded America Makes IMPACT 1.0 and 2.0 programs totaling over $2.5M.
3.
Fully qualified aerospace aluminum castings produced for US Air Force aircraft.
3.
Documented energy savings of up to 90% compared to conventional casting processes.

Strategic Partnership Network

Our partnerships extend reach across the full supply chain — from prototype to high-volume production:

1.
4+ year Partnership with Signicast (Form Technologies), one of North America's largest investment casting operations.
2.
Partnerships with Shellcast (Michigan), Metaltek (Wisconsin), Techcastings (Indiana), Triax (Arizona).
3.
Collaborative programs with Oak Ridge National Laboratory through the DOE HPC4EI initiative.
3.
Member of America Makes.
3.
Member of the Defense Industrial Base Consortium.
3.
Member of the Cornerstone OTA.

Service Areas Across the United States

We ship nationwide from Atlanta, Georgia, with full ITAR compliance for defense programs:

Aerospace clusters: Seattle, Florida, Southern California, Colorado and Texas

Medical device corridors: Minneapolis, Boston, and California

Automotive centers: Detroit, South Carolina, and Alabama

Direct technical consultation is available across all U.S. time zones.

Get Started with Casting Grade Alloys Today

Starting a project is straightforward. Submit your CAD file, specify your alloy and quantity, and our engineering team takes it from there — through shell design, ceramic printing, thermal processing, and metal pour. Reach us through any of the following:

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

Our team is available Monday–Friday, 8am–5pm ET.

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Frequently Asked Questions About Casting Grade Alloys

A casting grade alloy is a metal composition formulated for optimal performance in the casting process — balancing fluidity in the molten state, solidification behavior, and final mechanical properties. Unlike wrought alloys, casting grade alloys are engineered to fill complex mold geometries, minimize shrinkage defects, and achieve target tensile strength, corrosion resistance, or high-temperature capability in the as-cast or heat-treated condition.

The most commonly specified investment casting grade alloys span five families: stainless steels (304, 316, 17-4 PH, 15-5 PH), aluminum alloys (A356, A357), nickel superalloys (Inconel 625, IN 718, MAR-M247), cobalt alloys (ASTM F75), and tool steels (S7, 4140). Alloy selection depends on operating temperature, corrosion environment, mechanical load requirements, and industry-specific regulatory specifications.

Rapid Precision Castings ships to engineering and manufacturing teams nationwide from our Georgia facility. We serve aerospace, defense, medical, and industrial programs across all U.S. regions — with ITAR-compliant logistics for defense customers and remote engineering consultation available for any project. Contact us to discuss your requirements.