720185MegaShellClosedGRD Development of PrototypeInnovate UKThis project aims to develop a novel process for manufacturing very large, thin-wall ceramic shell moulds capable of producing large castings much nearer to net shape than possible with sand-moulded casting. Castings manufactured from sand moulds (the only available technique for castings of the size in question) fall well short of customer expectations and needs. New specifications are emerging that will further challenge sand moulded castings, particularly from the standpoint of precision of form, surface finish and integrity. Innovative technology is urgently required to produce high integrity castings with higher performance and lower total costs. The project proposes a versatile way to make very large patterns with great precision and fine surface finish, then reproduce these attributes in moulds made of novel ceramic materials that are strong enough to endure the casting process, but capable of being removed without damaging the component. The proposed MEGAshell® process has the potential to manufacture castings with the integrity normally associated with the Lost Wax process, but of a size and weight far beyond the capability of a process with a pedigree of manufacturing civil aero-engine blades and vanes. The intention is to take techniques and materials that Cti has proved at a research level and turn them into repeatable and robust solutions that its Members and licensees can use to produce high value precision castings relatively quickly and economically. By doing so, it will enable UK foundries (for which Cti acts as a ‘corporate research centre’) to compete with low cost countries. The UK metal casting industry is a key player in the global market, adding £2.6bn a year to the UK economy and employing 30,000 in 500 companies of which the vast majority are SMEs. The project will help to protect and grow some of these small businesses by providing them with the capability to enhance the competitive position of most sectors of UK manufacturing.