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Capability Statement
Evaluate the production path behind an unavailable casting—technical data, tooling condition, supplier capability, process route, inspection and approval requirements—before committing to a replacement strategy.
An aircraft casting can become difficult to source even when the geometry is known. Original wax-pattern tooling may be missing, damaged, or uneconomical to recreate. The former foundry may have exited the market, lost a required capability, or no longer support the alloy, inspection plan, or production volume.
The first task is not simply finding another supplier. It is determining what controlled technical evidence exists, which manufacturing assumptions must be reconstructed, and who retains authority for design, material, process, inspection, qualification, and airworthiness decisions.
Confirm whether dies, wax tooling, core tooling, fixtures, and gauges exist; who owns them; their condition; and whether they reflect the current approved configuration.
Establish the revision status of CAD, drawings, specifications, material requirements, tolerances, process notes, inspection criteria, and prior production records.
Document whether the constraint is supplier exit, capability loss, minimum-order economics, excessive lead time, unavailable tooling, or an approval limitation.
Rebuild wax-pattern and related tooling when demand, data quality, schedule, economics, and approval requirements justify restoring the former route.
Evaluate a new foundry against alloy, casting complexity, process controls, inspection capability, capacity, and program-specific source requirements.
Use an engineering-led change when the original configuration, material, interface, or manufacturing assumptions should not be reproduced unchanged.
Assess directly printed ceramic shells when avoiding conventional wax-pattern tooling may improve feasibility for limited quantities, complex internal features, or schedule-constrained requirements.
Directly printed ceramic shells can remove the need to reproduce a wax-pattern die and injected wax patterns. Integrated cores may also be produced as part of the mold architecture where geometry and the process plan support it.
This may reopen an investment-casting route when tooling cost, availability, complex internal geometry, or limited quantity makes the traditional wax path difficult to justify.
The mold-production method does not bypass design authority, material requirements, casting-process controls, inspection, traceability, first-article obligations, qualification, configuration control, or airworthiness requirements.
Those obligations must be defined by the applicable customer, program, design authority, and regulatory framework.
Controls applicability, approved configuration, engineering disposition, qualification basis, and authorization for service use.
Develops the manufacturing route, process controls, material execution, foundry documentation, and production evidence within the agreed scope.
Define and execute dimensional, material, nondestructive, first-article, traceability, and acceptance requirements assigned by the program.
Connect planned sustainment, AOG response, data readiness, digital inventory, and configuration control.
Review the broader casting-reproduction pathway when an unavailable component must be assessed from controlled data or an existing part.
Use the urgent-intake pathway when an aircraft-on-ground requirement needs rapid technical triage and route selection.
Send the part number, available technical data, tooling and supplier history, quantity, schedule, and known approval constraints. The initial review focuses on what evidence exists, what failed in the former route, and which recovery paths merit technical evaluation.