The $13 million capital investment expands the Groton site’s operational footprint by 17,000 square feet and introduces next-generation automation and environmental control systems.
Equipped with three high-precision 6-axis robots and the industry-leading IC-Crystal Shell Management System, the new line significantly enhances production capacity, part quality, and operational reliability.
“Our new fully automated shell system isn’t just a machinery upgrade - it’s a strategic leap forward,” said Mike Looney, General Manager at Doncasters Groton.
“This investment dramatically enhances our efficiency, precision, and capacity, enabling us to take on more complex, high-volume aerospace products. It positions us to meet rising industry demand and deliver unmatched quality to our customers around the globe.”
The former shell system - installed in the 1980s - suffered from limited capacity, minimal process control, and frequent downtime due to heavy reliance on manual operations.
The new system addresses these challenges with multiple benefits, including a quadrupled output capacity, from 10 to 40 molds per day; a minimised process downtime through full automation and telemetry-enabled quality tracking; advanced environmental controls and efficient processing; and accelerated turnaround times through stable, rapid drying and optimised shell handling.
In addition, the shell line includes 6-axis robotics, IC-Crystal Shell Management which tracks all critical-to-quality parameters, environmental precision with maintains strict temperature (±2°F) and humidity (below 20 per cent), and low-maintenance upgrades.
To date, 48 molds across 6 part families have been successfully substantiated in the new system, Doncasters said. The first phase of legacy system decommissioning is nearly complete, with final demolition expected by October of this year.
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