buyCASTINGS Evaluating Production of Composite Products

Dayton Development Coalition, a Miami Valley Economic Development Organization has recently awarded buyCASTINGS’ team a $10,000 Development Services Grant. The project kick-off meeting started in mid-March 2011. The grant is being managed by the Edison Materials Technology Center (EMTEC) a non-profit agency of Kettering, Ohio. Dwight Rust, President of DARCO Consulting, Inc., will conduct and manage the market study. Dwight has over 23 years experience in various urethane products including rigid, semi-rigid, and flexible foam from his tenure at the Inland Division of General Motors in Dayton, OH.

buyCASTINGS.com launched FOPAT Production Inc. in 2008 to commercialize FOPAT, the advanced materials foam technology which has been perfected over the past several years for the investment casting industry. However, over the years, we have seen customer requests for foam composites for various other markets. Before launching a composites business or conducting further product development of composites applications, buyCASTINGS sought a Center of Innovation’s EDA Grant provided by the Dayton Development Coalition to conduct a market study to quantify the various applications, market size, product performance requirements, competition, cost-benefit analysis, and the investment pay-off analysis of foam based composite commercial products.

CALS or Composite and Lightweight Structures, LLC will conduct the commercial work for the composite markets. CALS is a wholly owned subsidiary of buyCASTINGS.com, Inc., conducting business since 1995 and has worked on multiple projects dealing with prototypes and composite materials for various markets. The unique aspect that CALS can bring is the production of cost effective cores with controlled properties that can be readily customized for military applications and commercial markets.

We believe that there is a strong pull from the military with the need of lightweight sandwich materials. There are also several large commercial opportunities (some of which are highlighted in the photos here). “This grant will enable us to determine where we should focus and invest for future job creation as well as for the best return on investment for our shareholders,” said Neil Chaudhry, buyCASTINGS Chief Operating Officer.

CALS foam cores have various characteristics that make it unique: the foam can be bonded to a wide range of materials during or after the molding process; stiffeners can be encapsulated such as Nomex®, Kevlar®, Etc.; cores stand up to temperature extremes and exposure to water, ultraviolet (UV) rays, oxygen, oil, grease, and other chemicals and can provide electrical conductivity control; CALS foam cores are precision molded to custom controlled skin, surface finish, and texture. The core properties can be tailored to provide conductivity or insulation or other properties as required by use of fillers, additives, conductive or insulating materials added during the molding process.

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