INVESTMENT CASTING

Every critical part
starts as poured metal.

Investment casting is the only process that can produce the critical components needed to build jet engines, nuclear and gas turbines, industrial equipment, drones, medical devices, and much more.

THE PROBLEM

A $250B market,
hollowing out.

The U.S. had 6,150 foundries in 1955. Fewer than 1,700 remain, and only a few dozen are qualified today for the highest end aerospace/defense work that keeps our nation running. The rest were consolidated, offshored, or simply closed.

The result: the highest-performance parts on earth are increasingly made in factories with 2–3 year lead times and no redundancy when supply chains break.

Foundry workers at a traditional metalcasting operation

THE UNLOCK

Physics were never
the problem.

The investment casting process has worked for three millennia. But over half of casting cost is direct labor and rework. Every step is manual. Investment casting needs a software automation layer and modern technology to survive.

WHAT WE’RE BUILDING

FoundryOS.

The modern foundry is software defined, automated, and AI enabled.

FoundryOS interprets part geometries, generates tooling-free patterns, and automates process control from shell building through pour and inspection, with full traceability from melt to delivery.

NASA A15 Bracket, designed/cast with FoundryOS

A15 bracket developed by NASA as part of the Text-to-Spaceship and Evolved Structures research, cast by Fabri. CAD to casting in 5 days. Winner of the 2026 AFS Casting of the Year (Small Foundry).

THE PROCESS

description01DesignCAD-to-casting in under a week. FoundryOS reads part geometry and generates process parameters automatically.

deployed_code023D PrintTooling-free patterns printed directly from CAD via DLP/SLA resin. No hard tooling, no 6-month lead time.

factory03ShellCeramic shell built layer by layer under software-controlled humidity and temperature.

local_fire_department04CastMolten metal poured into the shell. Process parameters logged and traced in real time.

search05InspectFull dimensional and NDT inspection. Every part fully traceable from melt to delivery.

OUR MISSION

The parts that define
American power
will be cast here.

Let’s talk.

Contact View Capabilities

Every critical partstarts as poured metal.

A $250B market,hollowing out.