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Aerospace

Doncasters expands Groton site with new shell line

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



Image courtesy Doncasters

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.

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“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.

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To date, 48 molds across six 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.

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