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 buyCASTINGS put together a team of member companies led by Energy
Industries of Ohio for development and prototype  fabrication of a modular coil Winding form 5000 lb stainless steel casting (shown here) which is part of PPPL’s (Princeton Plasma Physics Laboratory) National Compact Stellarator Experiment (NCSX).
The Princeton Plasma Physics Laboratory is one of the leading research organizations for fusion research. According to the Princeton Plasma Physics Laboratory, the National Compact Stellarator Experiment is planned as the centerpiece of the U.S. effort to develop the physics and to determine the attractiveness of the compact stellarator as the basis for a fusion power reactor.
Fusion power holds unlimited potential as a clean source of
energy, i.e. one that does not produce significant radioactive waste. The NCSX project is now in conceptual design. Detailed engineering design began in 2002 and construction is to be completed in June of 2007. A photo of the conceptual compact stellarator is shown to the left.
 buyCASTINGS recently assembled a similar team and managed the project activities to plan, produce and deliver the 1/10th scale investment cast vacuum vessel for the NCSX program for PPPL
(See Netcaster Issue 5). Although the complexity and scope of this new project is much greater, the management and technical approach will be the same as the cast vacuum vessel project which will be to reduce cost, minimize risk, and manage schedule to ensure project success. It is believed because of the complexity of the project no one company has all the resources to complete the project on time and within cost constraints.
The team building experience of buyCASTINGS makes this a perfect match for this
initiative.
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The team members for the Modular Coil Winding Form project include: Energy Industries of Ohio (EIO) of Cleveland, Ohio, Atlantic Technical Components of Middletown, New York, MetalTek International of Peavley, Missouri, Magna Machine of Cincinnati, Ohio, CA Lawton Co Pattern Division of DePere, Wisconsin, Deformation Control Technology of Cleveland, Ohio, Finite Solutions of Cincinnati, Ohio, and Altair Engineering of Columbus, Ohio. Each team member brings unique strengths to the project making the team as a whole very valuable.
Energy Industries of Ohio with assistance from Atlantic Technical Components and buyCASTINGS, Inc. will manage the overall contract and all aspects of technical, financial, contractual, reporting, and schedule requirements to ensure that project requirements and product specifications are met and delivered on time and on budget.
The project team will address overall program risk reduction and dimensional stability of the casting by teaming with
several emerging technology suppliers such as Altair Engineering Deformation Control Technology and Finite Solutions. The Ability of EIO to choose the appropriate companies to work with adds much needed flexibility to a complex task.
C.A. Lawton Company, Pattern Division will provide CAD engineering and CNC Machine the very complex casting pattern and core boxes.
Magna Machine Company will provide 5 axis final machining and inspection of this very demanding shape.
MetalTek International will provide the casting and processing aspects of the project. MetalTek is an ISO-9000 certified foundry with experience in the manufacturing and post processing of very large castings such as the one required for the NCSX project.
The overall objective of this project is to conduct manufacturing development for the three modular coil winding form shapes, which are repeated six times to form the support structure for the main sellarator coils, the production of a full-scale prototype of one winding form, and, based on these activities, deliver a firm fixed price and schedule proposal for the eighteen production castings for the National Compact Stellarator Experiment. The highly skilled team members will combine their expertise under the project management and oversight of EIO in order to achieve this objective successfully.
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