From CAD to Cast Metal in Days, Not Months — Zero Tooling Investment | ITAR Registered | Made in USA | Capability Statement
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Industrial Gas Turbine Parts | Component Repair & Precision Casting

Advanced manufacturing solutions for critical gas turbine components — 90% energy reduction, 50% cost savings, zero tooling required.

We manufacture industrial gas turbine parts using breakthrough ceramic 3D printing technology that eliminates traditional tooling, compresses lead times from months to days, and unlocks superalloy casting capabilities that conventional foundries cannot match.

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Call Us: 470-225-6987

Benefits of Industrial Gas Turbine Parts Manufacturing in the United States

Zero Tooling Investment Required

Our LAMP™ technology prints ceramic shell molds directly from CAD files, eliminating $50,000–$200,000+ in conventional tooling costs and delivering three immediate advantages:

1.
Zero up-front tooling cost for first-article production.
2.
First parts in as little as 10 days versus 52–80 weeks conventionally.
3.
50% cost reduction versus traditional investment casting.
Eliminate Tooling Costs

90% Energy Reduction with Sustainable Casting

Our DirectPour™ process — validated through the U.S. DOE’s ARPA-E program with GE Vernova — delivers three measurable sustainability gains by eliminating seven of twelve conventional process steps:

1.
90% energy reduction versus traditional investment casting.
2.
90% scrap reduction, lowering raw material waste for high-value nickel superalloys.
3.
Quantifiable carbon footprint reduction to support Scope 1 and Scope 2 ESG reporting.
Learn About Sustainable Manufacturing

Advanced Superalloy Capabilities

Our facility processes the most demanding nickel superalloys for industrial gas turbine hot sections, with demonstrated IGT blade production in DS René 141 with cast-in film cooling holes. Three advanced capabilities set our process apart:

1.
Single-crystal and DS casting (CMSX-4, René N5, René 141, René 80) for first-stage blades and vanes above 1,000°C.
2.
Cast-in film cooling holes and integrated internal passages in a single printed shell operation.
3.
15-micron resolution LAMP™ printing with dimensional accuracy held to ±2 microns.
Discuss Your Alloy Requirements

Industry Applications

Power Generation Applications

We manufacture hot gas path components for natural gas, hydrogen-ready, and combined-cycle power facilities — parts that must endure extreme thermal cycling at firing temperatures exceeding 1,000°C. Our tooling-free LAMP™ process serves three critical application areas:

  • Turbine blades and nozzle guide vanes in single-crystal and directionally-solidified superalloys for first-stage hot gas path service.
  • Gas turbine fuel nozzles and combustion hardware with complex internal geometries and tight tolerances.
  • Shrouds, casings, and structural components for base-load and peaking power applications requiring long-term reliability.

Every component is cast to production investment casting standards with full traceability documentation.

High-Value Component Repair

Our SLE™ (Scanning Laser Epitaxy) technology delivers additive repair for damaged superalloy turbine components — restoring original metallurgical specifications without the cracking risks of conventional welding, including on non-weldable alloys like MAR-M247, René 80, and IN100. SLE™ restores mission-critical components across three categories:

  • Blade tip restoration and airfoil leading edge rebuilding with deposits exceeding 2mm per pass and matched crystal structure.
  • Dimensional restoration of hot gas path components for aerospace and IGT applications with 10% higher microhardness than cast substrate.
  • Substrate preparation for thermal barrier coating reapplication, extending service intervals, and reducing replacement part costs.

Fully dense, crack-free deposits with epitaxial continuity make SLE™ the only repair solution for the industry’s most demanding superalloys.

Turbine Applications Gallery

Our Revolutionary Manufacturing Process

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Digital Design and Engineering Optimization

Our engineers optimize your CAD models for ceramic shell production — eliminating separate core tooling by integrating all internal features into a single monolithic structure. Three foundational outcomes drive this phase:

1.
Thermal analysis and stress optimization to ensure casting integrity across single-crystal and DS solidification cycles.
2.
Integrated core design that removes separately injected ceramic cores and their associated tooling.
3.
Manufacturing feasibility assessment with design-for-casting recommendations to maximize yield and reduce part cost.

Every design review is completed before a single gram of ceramic is printed.

Start Your Design Review
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LAMP™ Ceramic 3D Printing Production

Our proprietary LAMP™ process prints fully integrated ceramic shells — with internal cores, cooling passages, and film cooling holes — in a single operation at 15-micron resolution, with no assembly, no tooling, and no wax patterns required. Three performance capabilities set LAMP™ apart:

1.
4.1 million UV beams at 15-micron pixel size for precision reproduction of complex airfoil geometries.
2.
Surface finish below 4 microns RMS and >99.5% density after thermal processing, meeting aerospace casting quality standards.
3.
Throughput of 36,000 cm³ of printed molds per day, supporting both prototype and series production schedules.

No other ceramic printing process matches this combination of resolution, surface quality, and production throughput.

Learn About LAMP™ Technology
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Thermal Processing and Metal Casting

Sintered ceramic shells are cast via DirectPour™ — at our Atlanta, GA facility or delivered ready-to-pour to customer foundries — with strict thermal gradient control for single-crystal and DS microstructures. Three quality assurance commitments back every casting:

1.
Full traceability documentation — chemistry, metallurgical quality, and mechanical property data.
2.
Radiographic and dimensional inspection to confirm conformance prior to shipment.
3.
Air-melt and vacuum-melt compatibility across the full spectrum of turbine alloy families.

All castings meet production investment casting standards before leaving our facility.

Schedule Your Casting

Why Choose Rapid Precision Castings?

Proven Government and Industry Validation

With $8+ million in federal funding — including a $3.3M ARPA-E award with GE Vernova and $1.8M through America Makes IMPACT — our technology is validated at the highest levels of government and industry compliance:

1.
ARPA-E validation for energy-efficient turbine casting with GE Vernova.
2.
America Makes IMPACT 1.0 and 2.0 funding for defense turbine casting maturation.
3.
Active ITAR registration and DFARS-compliant manufacturing for controlled defense programs.
View Our Credentials

Decade-Long GE Partnership Excellence

Our 10+ year collaboration with GE Vernova validates LAMP™ ceramic 3D printing across joint ARPA-E execution, casting qualification for GE’s power business, and ongoing advanced gas turbine development. Three dimensions confirm our manufacturing capability:

1.
Production-scale shell performance for hot gas path components under real operating conditions.
2.
Casting quality and process reliability data accumulated across a decade of joint development.
3.
Energy savings quantification independently validated through a federally funded research program.
Learn About Our GE Partnership

Revolutionary Technology Leadership

With 26+ patents across six countries, our Digital Foundry™ delivers three proprietary technologies unavailable through any conventional foundry or competing additive process:

1.
LAMP™ — the only ceramic 3D printing process validated for single-crystal and DS superalloy casting at production scale.
2.
SLE™ — the only additive repair process with demonstrated epitaxial bonding in non-weldable turbine superalloys.
3.
DirectPour™ — an end-to-end casting service delivering ready-to-pour shells or finished castings in as little as 10 days.
Discover Our Technology

Get Started with Advanced Gas Turbine Parts Manufacturing Today

Ready to transform your turbine component manufacturing with technology that eliminates tooling, reduces costs by 50%, and delivers first parts in as little as 10 days? Our engineering team provides comprehensive support from initial design review through final component delivery:

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

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Frequently Asked Questions

Gas turbines have three primary sections: the compressor, combustor, and turbine. Key hot gas path components include turbine blades, nozzle guide vanes, shrouds, transition pieces, and combustor liners — the high-criticality parts where our LAMP™ and DirectPour™ deliver the greatest advantage.

The four main types are industrial gas turbines (power generation and mechanical drive), aeroderivative turbines (flexible grid support), microturbines (distributed power), and marine gas turbines (naval propulsion). Our LAMP™ tooling-free casting process serves all four categories with the same rapid-turn production capability.

Rapid Precision Castings operates from Atlanta, Georgia, providing ITAR-registered, DFARS-compliant gas turbine services and precision castings to power operators, defense contractors, and turbine OEMs nationwide. Our Made-in-USA Digital Foundry™ delivers single-crystal and DS superalloy casting capabilities — including replacement parts and component repair — that traditional foundries cannot match.