aerospace castings by Shellcast


Shellcast has participated in many aerospace milestones over the last four decades and is frequently recognized with supplier awards for consistent product quality and delivery standards.
Shellcast is a supplier of aluminum investment castings for many aerospace, and defense industry programs.

Investment Casting

Shellcast is a fully integrated, Canadian owned company, founded by its President, Bodo B. Morgenstern, in 1971.  Located in Montreal, Canada, it is one of the major manufacturers of aluminum precision investment castings by the lost wax process.

We produce high-quality aluminum alloy castings using the shell process on automated production lines employing robotics. Casting sizes range from less than 1 in² (645 mm²) plan area, to a volume size fitting into a 3.5 ft. cube, with a single axis up to a length of 40 inches.

Our QMS is certified to ISO 9001:2015, AS9100D. We are also certified to Nadcap and work in compliance with other standards such as ASTM, AMS, MIL. Production processes are evaluated under Statistical Process Control (SPC) using Six-Sigma Data. The Company facilities comprise approximately 66,000 ft².  All casting relevant processes are performed in-house.  This includes a non-destructive test lab (NDT) for X-Ray and Penetrant inspection, a destructive test lab, a chemical test lab with arc emission spectrometer, heat treatment facility, CAD systems and CMM equipment.

Rapid Prototyping

Shellcast has pioneered and developed a system to produce rapid prototype castings without hard tooling by utilizing resin models produced from a variety of processes. This prototyping capability allows for casting production in as little as four weeks.