Rapid Fabrication Program
Delivering High Quality Thermal Components on Compressed Timeframes
Cast Aluminum Solutions is respected supplier of precision engineered thermal components to the semiconductor, medical device, commercial foodservice, and aerospace markets.
Our Rapid Fab Program applies this design and manufacturing expertise toward the production of high-quality industrial products, using standardized components, delivered on abbreviated timeframes.
- What You Need: Perfect for replacement parts, prototypes, proof-of-concepts, and low-volume runs
- When You Need It: As short as 2-3 weeks on non-heated parts, 3-4 weeks on heated components
- Components are In-Stock: The program is based on the use of standardized, in-stock or readily-available substrate materials, heaters, temperature sensors, and component fittings.
- Many Options: Stainless steel and aluminum substrate options. Heater choices include tubular, cable, and cartridge heaters, with several options for temperature sensors, lead wires and power connectors.
- Fabricated for Performance: CAS employs distinct fabrication techniques, matched to your substrate & heater pairing, ensuring each design configuration performs at a high level over a long lifecycle.
- Its Your Design: Rapid Fab projects are custom-machined to meet each customer's unique form, fit, and function specifications..
Let's Get Started on Your Project
The below will walk you through the details of our Rapid Fabrication Program, and allow you to Request a Quote.
This large replacement heater was made to fit a cryogenic gas vaporizing application.
Prototype of a wafer chuck for the semiconductor wafer processing application.
Semi chamber heater prototype featuring dual Mate-N-Lok power connectors.
This tubular heater in SST has outstanding heat transfer and requires no backing plate.
This foodservice grill prototype features multiple cartridge heaters in an aluminum substrate.
Made for a concrete block drying process, this is small but rugged industrial heater.
Aluminum with tubular element and Interference Fit Construction for a specialty industrial heater.
Specialty heater for the semiconductor industry, featuring groove-set cooling tube.
Tubular heater in aluminum with 4-pin CPC and Dual-Junction K-Type TC
Click Picture for Rapid Fab Examples
- The Rapid Fab Program utilizes a menu-driven process to select substrate materials, heaters, temperature sensors, leadwires, and power connectors. See the tables below for the full list of options, or click the "Quote Request Tool" to get started.
- Dimensions and surface finishes are determined by the customer. The Quote Request Tool will allow you to upload PDF docs for your project's Schematics or Dimensional Drawings.
- Rapid Fab quotes are generally completed and sent to customers via email within 24 hours.
- Parts are not required to have a heating or cooling function.
- Projects utilizing tubular heating elements will be constructed using our proprietary Interference Fit Construction. This proprietary technique optimizes thermal transfer and ensures long heater life.
- Projects utilizing cable heaters will use a milled groove construction, and require a backing plate.
Substrate Options
- Aluminum and Stainless Steel substrate materials are offered
- The size limitations noted here denote max dimensions for Rapid Fabrication program parts
- Parts with larger substrate dimensions may still be manufactured, although not part of the Rapid Fab program
Heater Options: Tubular Heaters
Tubular Heaters are integrated via CAS's Interference Fit Construction (IFC), delivering superior heat transfer due to the heater’s intimate contact with the substrate.
- Cold Ends: 2 - 6 inches
- Tubular heaters can be operated at below the stated voltages, resulting in reduced (derated) wattage output.
Heater Options: Cable Heaters
Cable Heaters require a backing plate, and will utilize a standard Milled Groove process to integrate the heater with the substrate.
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Cable heaters can be operated at below the stated voltages, resulting in reduced (derated) wattage output.
Tubular or Cable Heater? Consider These Factors
The choice of Tubular vs. Cable Heater affects the construction format of your part. Tubular Heaters are integrated using our proprietary Interference Fit Construction (IFC), causing the heater to have intimate contact with the substrate. Cable Heaters are integrated using a standard Milled Groove process, which requires the integration of backing plates.
Tubular Heaters are integrated to substrates using our IFC technique, which results in optimal heat transfer and longer heater life.
Cable Heaters are integrated via a traditional Milled Groove process, requiring the integration of a backing plate or similar mechanism.
Heater Options: Cartridge Heaters
Substrates can be machined to accommodate single heaters or multiple Cartridge Heaters.
- Cartridge Heaters can be operated at below the stated voltages, resulting in reduced (derated) wattage output.
- Power leads are 24" (60 cm) Teflon or MGT
Temperature Sensors
We offer popular TC and RTD Temperature Sensors, which can be integrated into heated parts to control operating temps and protect against overheating.
Power Connectors
These industry-standard Power Connector options allow customers to easily integrate Rapid Fab parts into their existing process machine.
Rapid Fabrication Quote Request Tool
Please click through the below interface, selecting the options required to build your Rapid Fab part. At the end, you’ll be allowed to upload a schematic or print of your design. A CAS Technician will then contact you to follow-up and quote the project. If certain aspects of your project are not addressed in the Quote Request Tool, that’s okay, as those issues can be discuss with your CAS Technician.
