Defense Logistics Agency and buyCASTINGS Achieve Success For Casting Efficiencies

In 2009 buyCASTINGS.com, Inc. was awarded two contracts by the Defense Logistics Agency (DLA). One titled, “Reduced Costs and Lead Times for Discrete Parts Manufacturing of Cast Metal Components”. This was actually an extension of an earlier Small Business Innovative Research , ( SBIR ). SBIR helped to launch the FOPAT process in making foam patterns for investment castings at reduced costs.

The second contract was titled, “Implementation of Innovative Metal Casting Technologies to Lower DoD Procurement Costs and Reduce Lead Times”. It provided research and development for the Industrial Base Innovation Fund II, ( IBIF II ) to further advance the use of FOPAT in the investment casting industry for parts needed by the DLA.

Both contracts will continue through the fall of 2011. The SBIR contract has helped to fund research into different tooling materials helping buyCASTINGS characterize the advantages and disadvantages of each when coupled with FOPAT. We have numerous examples of being able to produce tooling in less than 3 weeks at significantly reduced costs. The contract has also funded research leading to the verification of reduced energy in the pattern making process. It takes 70% less energy to make a FOPAT pattern compared to a wax pattern. Studies show dimensional stability and repeatability far exceeds the wax process. Patterns have been successfully made which are virtually impossible to make with wax. The IBIF contract has aided buyCASTINGS to expand the number of foundries that have conducted tests with FOPAT patterns. The purpose of the contract is to expand the number of suppliers available to the DLA to make needed spare parts. To date, over 50 foundries have the opportunity to make castings from FOPAT patterns. In addition, over 25 different parts have been successfully made and sampled. As the success grows it is apparent that FOPAT has demonstrated significant savings in time, up front tooling costs and finished part cost, and, provide superior dimensional accuracy.

The partnership with the DLA has been beneficial for both organizations. It has brought opportunities for foundries to supply needed investment castings for our Military. The future looks bright for FOPAT thanks in part to the contracts awarded to buyCASTINGS.com, Inc. by the DLA.

Consider if you’re an investment casting foundry and you haven’t tried FOPAT yet - you should. If you want the opportunity to supply the DLA with parts, FOPAT can give you the edge to win the bid. Or, if you’re a casting user and you need quick response for prototypes or better dimensional accuracy at a lower price, you owe it to yourself to contact FOPAT Production, Inc. (a division of buyCASTINGS.com, Inc.) and see how FOPAT can be part of your future too!

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