Fabrication Services
Prototype Casting
Sand casting and direct-print ceramic mold casting with small-scale vacuum induction melting for advanced alloys.
Example Work
Representative examples. Actual parts vary based on customer specifications.
Availability Note: Some advanced services are limited while equipment recovery continues after flood damage. If you have a deadline, include it in your request and we will tell you what is realistic.
This capability includes both sand casting and direct-print ceramic mold casting. Process selection depends on geometry, alloy, and performance requirements. We help determine the appropriate pathway during engineering review.
Flagship Offering
Integrated Casting Workflow
We offer a complete prototype pathway from direct-print ceramic mold investment casting or sand casting through final machining and basic inspection. Heat treatment can be coordinated as a managed service when required. This reduces vendor handoffs and accelerates iteration.
1
CAD & Engineering Review
2
Mold Selection
Sand or Direct-Print Ceramic
3
Casting
4
Heat Treat
Managed service, when required
5
CNC Machining to Print
6
Basic Dimensional Inspection
Workflow steps vary by alloy and geometry.
What This Solves
- •Reduces multi-vendor coordination
- •Maintains traceability across casting and machining
- •Supports dimensional refinement after shrink
- •Accelerates prototype iteration cycles
Final Deliverables
- •Cast part
- •Heat treated (if required)
- •Machined critical surfaces to print
- •Basic dimensional inspection report
- •Process summary documentation
Managed Heat Treatment
When alloy systems require heat treatment, we coordinate with qualified partners and manage the process as part of the casting workflow. Heat treatment specifications are reviewed during engineering intake.
- •Alloy-specific heat treat selection
- •Managed vendor coordination
- •Linked documentation
- •Turnaround integrated into overall schedule
Heat treatment is performed by external partners. Availability and lead time vary by alloy.
Typical Lead Time: Integrated workflow: 4–10 weeks depending on alloy, machining scope, and heat treatment requirements.
This integrated pathway is designed for prototype and pre-production validation. Not intended for production volumes.
Casting Pathways
Standard Process
Sand Cast Prototypes
Sand casting is available for larger, simpler, or more forgiving geometries. This method supports faster turnaround and lower cost when ultra-fine internal detail or advanced alloy control is not required.
For simple geometries using in-house 3D printed plugs and readily available alloys, expedited turnaround may be possible.
Expedited 24-Hour Option (When Eligible)
In certain cases, simple geometry parts can be turned around in approximately 24 hours. This pathway requires:
- •Simple, open geometry
- •No complex cores
- •In-house 3D printed plug
- •Readily available alloy
- •Engineering approval prior to scheduling
Expedited work is subject to material availability and shop capacity.
Not all projects qualify. Engineering review required.
Best For:
- •Larger sections
- •Structural brackets and housings
- •Non-critical geometry validation
- •Cost-sensitive prototypes
- •Aluminum and common ferrous alloys
Typical Lead Time: 2–4 weeks standard turnaround
Expedited 24-hour option available for qualifying parts.
• More forgiving dimensional tolerance
• Surface finish differs from ceramic mold casting
• Ideal for early-stage iteration
Advanced Process
Direct-Print Ceramic Mold Casting
Direct 3D printed ceramic molds enable complex internal features, thinner walls, and tighter dimensional control compared to traditional sand casting.
Best For:
- •Complex internal passages
- •Turbine-like geometries
- •Thin sections
- •Advanced alloys
- •Pre-production validation
Typical Lead Time: 3–8 weeks depending on alloy and geometry
Ceramic Mold Process
We print ceramic molds directly using engineered, high solid-loading resin systems. This eliminates traditional wax tooling and accelerates iteration on complex internal geometry.
Molds are processed under controlled burnout and sintering schedules and linked to documented melt records. Each casting is part of a traceable development workflow.
Process Overview (Ceramic Mold Pathway)
1
CAD Review & Alloy Selection
2
Ceramic Mold Print
Direct print, high solid loading
3
Controlled Burnout & Sinter
4
Vacuum Induction Melt
If required
5
Cast, Inspect, Document
Process steps vary by alloy class and geometry.
Advanced Capability
Advanced Alloy Support (Ceramic Mold + VIM Pathway)
Titanium Alloys
- •Prototype-scale melt quantities
- •Controlled melt environment
- •Engineering review required
- •Ideal for geometry validation and early hardware
Nickel-Based Superalloys
- •Support for Inconel-class and Mar-series materials
- •Small-batch VIM capability
- •Designed for high-temperature prototype components
Maraging & Specialty Steels
- •Controlled chemistry melts (prototype scale)
- •Suitable for tooling, structural R&D, and high-strength applications
Cobalt & High-Performance Copper Alloys
- •R&D quantities
- •Complex geometry support
- •Application-specific review required
All advanced alloys subject to engineering review and melt capacity constraints.
Small-Scale VIM Capability
Our small-scale Vacuum Induction Melter enables controlled atmosphere melting of reactive and high-performance alloys. This supports titanium and nickel-based systems where oxidation control and melt chemistry stability are critical.
Controlled melt atmosphere
Small-batch volumes
Documented melt cycle
Resin batch → mold batch → melt batch traceability
What You Receive
- •Cast part(s)
- •Basic dimensional inspection
- •Melt record summary (when applicable)
- •Process notes to support iteration
What We Need From You
- •CAD files (STEP preferred)
- •Material requirements and alloy preferences
- •Critical dimensions and tolerances
- •Quantity and timeline
- •Application context
Scope & Review Notice
This is a prototype-scale capability. Not all geometries or alloys are accepted. Reactive alloys, thin sections, or critical-load components require engineering consultation prior to scheduling.
Quality Systems
The Backyard Shop operates with ISO 9001 and AS9100-aligned quality systems. Work follows documented processes, controlled revisions, and inspection checkpoints, executed under experienced supervision.
Ready to Cast?
Submit your CAD files and requirements for engineering review. We will assess castability, recommend the appropriate pathway, and provide a scoped proposal.