From CAD to Cast Metal in Days, Not Months — Zero Tooling Investment | ITAR Registered | Made in USA |
Capability Statement
We build new turbine blades and restore damaged ones, including blades in superalloys conventional welding cannot repair. MAR-M247, René 80, and IN100 crack under standard weld methods. Our Scanning Laser Epitaxy (SLE™) process rebuilds them crack-free while preserving single-crystal and directionally solidified grain structure.
Our industrial gas turbine casting service produces new blades in CMSX-4, René N5, René 141, and IN718, with cooling passages cast in rather than machined. First castings ship in 10 to 39 days instead of 12-plus months through traditional tooling. On the repair side, SLE™ restores blades in the alloys most MRO shops decline.
We cast new single-crystal, directionally solidified, and equiaxed superalloy blades without tooling. Send a CAD model and specify the alloy. No wax patterns, no core injection dies, and no tooling investment, which matters most on legacy blades where the original tooling is gone. Removing the tooling and wax pattern steps cuts manufacturing cost by up to 50%.
SLE™ repairs superalloy blades conventional welding cannot touch. MAR-M247, René 80, and IN100 crack under standard weld methods because of their high gamma-prime content. SLE avoids that mechanism and delivers fully dense, crack-free deposits.
We restore worn hot-section blades and airfoils to serviceable condition, rebuilding eroded tips, squealer tips, and damaged geometry while preserving the original microstructure and creep strength.
Single-crystal blades in CMSX-4, René N5, PWA 1480, and PWA 1484 carry no grain boundaries by design, and that absence is the source of their creep strength at hot-section temperatures. SLE rebuilds damaged sections while continuing the parent crystal orientation, so the repaired region matches the base metal structure.
If a repair vendor has told you an alloy is not weldable, this is the process built for that answer. SLE laser deposition bonds epitaxially to the substrate and produces crack-free builds with 10% higher microhardness than the cast base metal. We apply it to vanes, nozzles, and shrouds as well as blades.
Send us the blade if you are seeing any of the following.
We assess each blade before quoting. Repair timelines are quoted per job, set once we receive the damaged part and finish the assessment. If a part is beyond restoration, we will tell you, and we can quote a new casting instead.
All castings meet applicable ASTM standards and fall within Investment Casting Institute stated ranges. See the full casting grade alloy catalog.
For the full technical detail, see our SLE™ additive restoration process.
Yes. MAR-M247 is one of the alloys our SLE process was developed to handle. It cracks under conventional welding due to high gamma-prime content. SLE produces fully dense, crack-free deposits in it.
Yes. SLE deposits material epitaxially, meaning the new material continues the crystal orientation of the parent blade rather than forming new grains. The repaired section matches the base metal structure.
Conventional welding melts filler into a weld pool that solidifies as a separate structure, often cracking in high gamma-prime superalloys. SLE controls thermal conditions so the deposit grows from and continues the substrate crystal structure, avoiding the cracking mechanism.
Repair timelines are quoted per job. We set the schedule after we receive the damaged part and complete the assessment, because turnaround depends on the alloy, the extent of the damage, and the finishing your specification calls for.
First castings typically ship in 10 to 39 days depending on part complexity and alloy, compared with 3 to 12 months through traditional tooling-based investment casting.
No. Our DirectPour™ process prints the ceramic shell with integrated cores directly from your CAD model. There is no core die, no wax die, and no tooling investment.
Yes. Cores are printed as part of the monolithic shell, so internal cooling passages and film cooling holes are cast in rather than machined afterward.
CMSX-4, René N5, René 142, René 80, René 141, MAR-M247, IN100, IN718, IN625, IN713LC, and Ti-6Al-4V, among others.
Yes. We work across aviation hot-section components and industrial gas turbine parts.
We assess repair feasibility on non-weldable superalloys other vendors decline, and we quote new blade castings with no tooling investment. Send a drawing, a CAD file, or the part itself.
These records support the technology and research statements on this page. Government project records describe scope, participants and targets; they do not by themselves establish completion of every target.
Repair versus replacement
SLE repair feasibility depends on the base alloy and microstructure, damage location and depth, remaining wall or section, service history, coating condition, and the acceptance requirements of the responsible authority.
| Observed condition | Repair can be evaluated when | Replacement or new casting should be evaluated when | Verification required before release |
|---|---|---|---|
| Tip or squealer-tip material loss | Damage is localized, the remaining section is suitable for preparation, and the alloy and microstructure are confirmed | Loss is extensive, cooling features or minimum sections cannot be restored, or the acceptance basis is unavailable | Alloy identity, damage map, deposit plan, dimensions, NDT, finishing, coating, and customer acceptance |
| Leading or trailing edge damage | The defect is accessible, removal limits are defined, and repair can preserve required geometry and internal features | Damage affects inaccessible passages, exceeds engineering limits, or creates an uneconomic restoration scope | Wall and passage condition, repair limits, profile inspection, NDT, and applicable airworthiness or owner approval |
| Airfoil wall thinning, oxidation, or hot corrosion | Remaining material and damage depth can be measured and a qualified rebuild boundary can be established | Degradation is widespread, base material condition is uncertain, or the required life cannot be supported | Thickness mapping, material condition, deposit and heat-treatment plan, NDT, coating, and life or acceptance criteria |
| Cracking, impact damage, or unknown service history | Cracks and affected material can be fully characterized, the alloy is known, and the responsible authority defines repair limits | Crack extent, substrate condition, alloy identity, or approval basis cannot be established | Defect characterization, material identification, repair procedure, inspection, traceability, and responsible-authority approval |
| Obsolete part with no available replacement source | An approved repair basis exists and the component remains within repairable limits | Repair is not feasible but approved geometry, alloy, and qualification requirements support a replacement-casting program | Controlling technical data, source approval, first article, material and process qualification, NDT, dimensions, and traceability |