Advanced Manufacturing Reinvents Defense Castings, Strengthens Industrial Base
The convergence of the Fourth and Fifth Industrial Revolutions, compounded by rising geopolitical pressures, calls for a more agile and resilient supply chain. In response, the Department of War (DoW) has prioritized modernization within metal casting and forging (C&F) sectors, longstanding cornerstones of defense manufacturing that produce critical components for missiles, aircraft, and ground systems.
Despite their strategic importance, both industries face persistent challenges: aging infrastructure, labor-intensive processes, and limited scalability – issues that are especially acute in low- to medium-volume production environments. This is where the integration of advanced manufacturing technologies into C&F facilities plays a key role.
“The casting industry has experienced significant consolidation and reduction, with many suppliers moving overseas or across borders,” said Randy Altmann, General Manager at MetalTek’s International Wisconsin Investcast Division. “This underscores the urgent need for modernization to maintain a resilient and agile defense supply chain.”
To meet this challenge, the National Center for Defense Manufacturing and Machining (NCDMM) joined forces with MetalTek — a leader in missile fin and component casting — to launch the Advanced Manufacturing Cell (AMC) to Transform Missile Fin and Component Production initiative. The project set out to modernize the entire investment casting process, improving performance at every step, from mold preparation and melting to finishing and inspection.
The initiative offers a compelling, forward-looking blueprint on how advanced manufacturing can revitalize foundries and the broader C&F sector. Aligned with DoW strategic priorities, the project expanded manufacturing capacity, strengthened supply chain resilience, and modernized the defense industrial base (DIB), ensuring more efficient, reliable production of critical legacy components that enhance military capability, deterrence, and national security.
“This is a comprehensive, multi-year, multi-phase initiative that has demonstrated a significant step toward enhancing domestic production capabilities while fortifying the supply chain for the Army and the broader defense industrial base,” said Litsa Rubino, Program Manager at NCDMM.
MetalTek’s advanced manufacturing cell drives automation
MetalTek’s AMC project focused on modernizing casting operations by implementing automated processes, advanced data collection, additive manufacturing processes, and process simulation techniques. These enhancements addressed systemic issues, significantly optimizing the production of missile fins and components.
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