Doncasters’ Groton expansion reaches major milestone with new shell line commissioning as part of $13M investment drive

Doncasters is proud to announce the successful commissioning of a brand-new, fully automated shell line at its Groton facility – a major milestone within its 2025 Performance Improvement Plan and a key advancement in the company’s long-term manufacturing strategy.

The $13 million capital investment expands the Groton site’s operational footprint by 17,000 square feet and introduces next-generation automation and environmental control systems.

Equipped with three high-precision 6-axis robots and the industry-leading IC-Crystal Shell Management System, the new line significantly enhances production capacity, part quality, and operational reliability.

“Our new fully automated shell system isn’t just a machinery upgrade—it’s a strategic leap forward,” said Mike Looney, General Manager at Doncasters Groton.

“This investment dramatically enhances our efficiency, precision, and capacity, enabling us to take on more complex, high-volume aerospace products. It positions us to meet rising industry demand and deliver unmatched quality to our customers around the globe.”

The former shell system – installed in the 1980s – suffered from limited capacity, minimal process control, and frequent downtime due to heavy reliance on manual operations. The new system addresses these challenges with the following benefits:

• Quadruples output capacity – from 10 molds per day to 40 hangers per day
• Minimizes process downtime through full automation and telemetry-enabled quality tracking
• Improves mold quality with precise sanding and dipping performed by 6-axis robotic arms
• Reduces operating costs via advanced environmental controls and efficient processing
• Accelerates turnaround times through stable, rapid drying and optimized shell handling

Key System Features

• 6-axis robotics: Greater motion control reduces mold damage and ensures a superior surface finish
• IC-Crystal Shell Management: Tracks all critical-to-quality parameters—slurry conditions, equipment status, and environmental controls
• Environmental precision: Maintains strict temperature (±2°F) and humidity (below 20%) to prevent shell defects such as splits or cracks
• Engineered core packs: Eliminate manual handling, freeing up operators to focus on skilled tasks
• Low-maintenance upgrades: New systems replace high-impact equipment like fluidized beds and vertical sanders with more sustainable alternatives.

To date, 48 molds across 6 part families have been successfully substantiated in the new system.

The first phase of legacy system decommissioning is nearly complete, with final demolition expected by October.