Alphacasting: The best foundry in the world?
October 16, 2024
It’s a bold claim to fame, but Frederik Centazzo, Alphacasting’s president says there is good reason his investment casting business is booming.
Founded in 1991 and based in Montreal, Canada, Alphacasting – which is attending and supporting this year’s Japan International Aerospace Exhibition (16-19 October in Tokyo) – has made its mark over the last three decades as a specialist in precision investment casting for the aerospace as well as other sectors. Also known as lost wax casting, investment casting involves the pouring of molten metal into a mould created from a wax model. This wax model is then melted and drained away once the mould or shell is made.
“As a smaller, flexible foundry, we have built our reputation by focusing on quality, adaptability and on time delivery, allowing us to compete with larger foundries, particularly in high-tech sectors like the aerospace, defence, and medical industries,” explained Centazzo. The company’s high-quality castings which can produce custom moulded parts as complex, small or large as needed, have consistently earned it a place in the supply chain of industry giants including Airbus, Boeing, Bombardier, Raytheon, SpaceX, Honeywell, Triumph and Safran.
Although the company can cast with more than 120 different alloys, Alphacasting’s focus until recently has been on aluminium and steel. However, the last five years have seen the company increasingly cast with titanium, raising the standard in terms of precision, strength and efficiency. While this strategic shift was initially driven by opportunities in the medical sector, titanium is now more in demand by OEMs in the aerospace sector.
“Alphacasting identified a gap in the market for a smaller, more agile foundry capable of delivering high-quality, high-tech titanium as well as aluminium and steel castings. This flexibility, combined with our emphasis on quality has enabled us to seize opportunities and secure clients looking for a smaller, specialised supplier. We pride ourselves on being agile and able to deliver tailored services to our customers quickly and efficiently.”
Centazzo also credits the company’s success to its “highly skilled engineering team, which excel in managing a diverse range of alloy families, as well as a strong sales force that understands the importance of adaptability.”
Market challenges
The company – which was founded by Centazzo’s father, who at 87 years old remains actively involved in the business – currently employs more than 180 people. Most of the team is based in Montreal, although Alphacasting also has a presence in Europe and the US and recently opened an office in Vietnam in response to growing demand from customers in the region.
However, despite impressive growth, Centazzo underlined that challenges remain, primarily in terms of competition from larger foundries wary of Alphacasting’s success in the market, but also in terms of managing the businesses’ rapid growth and securing investment. “In Canada particularly, securing financial investment for companies that are involved in the defence industry is more difficult than for businesses involved in other sectors.”
Supply chain issues present another challenge. Centazzo revealed that while alloys such as stainless steel and aluminium are readily available, titanium is a different story. Geopolitical tensions have disrupted the supply chain, with Alphacasting no longer able to source the metal from Russia, a major titanium producer. “We’ve had to adapt by seeking alternative suppliers, including in China and more recently in the US, but this has come at a much higher cost,” revealed Centazzo.
“Subsequently, the price of titanium has nearly doubled, adding pressure on our cash flow. As a small company, the financial burden of purchasing large quantities of titanium upfront can be daunting.”
Still, the future looks positive. “We are proud to be the only foundry in Canada producing titanium castings and the only one on the East Coast of North America,” Centazzo continued.
Multiple alloy families
One of Alphacasting’s unique strengths is its ability to offer multiple alloy families under one roof. “We work with steel, aluminium and titanium, providing our customers with a comprehensive solution for their casting needs. This capability allows us to streamline the supply chain for our clients, offering better pricing and a more integrated service. For example, on the same project, we can handle different parts made from different alloys, making the process more efficient and cost-effective for our customers. One day we might be casting implants for the body and the next day a black box; every day throws up an exciting challenge.”
Demonstrating its commitment to maintaining the highest standards of quality across all aspects of its business, Alphacasting holds several key certifications. These include the industry recognised AS9100 standard and Nadcap certifications for special processes such as chemical milling, etching, welding, and heat treatment. “We are also constantly reinvesting in research and development (R&D) to improve our processes. One notable achievement is the development of the Koolcast process for aluminium alloys, which we co-developed with the Canadian government. This process allows us to produce thin-walled, high-mechanical-property aluminium parts, a capability shared by only a handful of foundries worldwide.
“Despite predictions that newer technologies like high-speed machining, powder metallurgy, and 3D printing would replace investment casting, our process remains strong. These newer methods are still more expensive and come with their own set of challenges, which means that investment casting remains a viable and cost-effective option for many applications.”
What’s more, the development of new aircraft in the commercial aerospace market have also led to rapid growth in demand for precision castings with Alphacasting working on numerous engine and airframe accessories, including gearboxes, cabin systems and other titanium structures.
Expansion on the horizon
Looking ahead, Centazzo’s goal is to continue growing Alphacasting both organically and through the strategic acquisition of smaller foundries. He has ambitious plans to grow the business from its current value of around C$20 million to C$40-C$50 million over the next five years. “I would also like to expand our footprint in Europe and the US. We have already secured several defence programs in Europe, and I believe there is significant potential for further growth in these regions,” he noted.
“Ultimately, what drives me is my passion for this industry. Every day brings new challenges and opportunities, and it is this constant evolution that keeps me engaged and excited about the future of Alphacasting. We strive to provide not just products but tailored solutions that meet the specific needs of each customer. That is what sets us apart and makes us the best foundry in the world.”
