July 2025 – Groton expansion reaches major milestone with new shell line commissioning
We’re excited to announce the successful commissioning of a brand-new, fully automated shell line at our Groton facility – a major milestone in our 2025 Performance Improvement Plan and a significant step forward in advancing our manufacturing capabilities.
This $13 million capital investment expands our site footprint by 17,000 square feet and introduces state-of-the-art automation and environmental control systems. With three 6-axis robots and the industry-leading IC-Crystal Shell Management System, the new line significantly increases capacity, enhances part quality, and improves production reliability.
Installed in the 1980s, our legacy shell system was outdated, limited in capacity, and prone to frequent downtime, with minimal process control and heavy reliance on manual operations that hindered overall efficiency.
In contrast, the new shell line:
- Quadruples output capacity – from 10 moulds per day to 40 hangers per day
- Minimises process downtime through automated system control and telemetry-supported quality tracking
- Improves mould quality with precision sanding and dipping using high-dexterity 6-axis robots
- Reduces operating costs through advanced environmental management and more efficient processing
- Accelerates turnaround times with faster stable drying and optimised shell handling
Key system features
- 6-axis robotics: Greater motion control reduces mould damage and enhances finish quality
- IC-Crystal Shell Management: Tracks all critical-to-quality variables, from environmental and slurry conditions to equipment status
- Environmental precision: Maintains temperature within ±2°F and relative humidity below 20%, reducing the risk of splits and cracks
- Engineered core packs: Eliminate manual material handling, enabling skilled operators to multitask more effectively
- Lower maintenance: Fluidised beds and vertical sanders replaced with lower-impact, lower-maintenance alternatives
Project timeline
- Customer Substantiation: 48 moulds across 6 part families successfully released into the system
- Legacy system and line decommissioning and demolition: The first phase of the decommissioning of the old system is nearly complete. Final phases of demolition are expected by October.
The Groton expansion exemplifies our ongoing commitment to investment, innovation, and operational excellence-strengthening our ability to deliver exceptional components to customers worldwide.
General Manager Mike Looney said: “This marks a significant milestone for the Doncasters Groton facility. We’ve successfully commissioned our new fully automated shell system, which introduces state-of-the-art automation and process control capabilities.
“This isn’t just about new machinery; it’s a strategic leap forward. This investment dramatically enhances our efficiency, precision, and capacity, enabling us to take on more complex and higher-volume products.
“For future growth, this means we are now exceptionally well-positioned to meet the escalating demands of the aerospace industry, innovate faster, and deliver unparalleled quality to our clients, solidifying our leadership in the market.”
