Shape Process Automation (SPA) announces a strategic collaboration with Acme Manufacturing to deliver a fully integrated automation solution for ceramic shell and core removal, and gate cut-off, for the investment casting industry.
The joint solution combines SPA’s robotic automation technology with Acme’s expertise in robotic material removal, creating a streamlined system that enhances precision finishing while increasing throughput in post-cast operations.
Aquarese CSR: Automated Shell and Core Removal
At the heart of this innovation is SPA’s Aquarese Ceramic Shell and Core Removal (CSR) system, a purpose-built platform engineered specifically for investment castings.
The CSR system features a robotic architecture paired with SPA’s Aqualance rotary nozzle, delivering greater energy control and repeatability compared to traditional manual methods. The Aqualance module accommodates multiple nozzle packages, enabling both aggressive bulk material removal and detailed finishing with rapid tool changeover and minimal downtime.
Integrated with the intuitive AquaTrack interface, the system provides job-specific process controls, real-time monitoring, data collection with MES connectivity, and remote diagnostics and maintenance support.
High-Performance Robotic Cut-Off Cell
Complementing the CSR system is Acme’s robotic cut-off cell, designed to integrate into existing production workflows.
As parts index into the work cell, a FANUC iRVision system determines the pick position of the casting tree. Parts are picked by the pour cup using a SCHUNK parallel pneumatic actuated gripper. Casting trees are presented to the vision system to identify the cut line.
Automated software offsets and programable HMI parameters allow operators to maintain consistent cut paths across a range of part sizes. Finished parts exit the cell on an automated conveyer and scrap is placed in a designated bin.
A key differentiator is the cut-off head, which are designed and built in-house by Acme. Built for high horsepower operation and heavy-duty use, the head delivers durability and cutting performance beyond conventional abrasive tool configurations.
Raising the Standard for Investment Casting Automation
Together, SPA and Acme have created a unified solution that addresses two of the most labor-intensive and variable stages in investment casting production. By integrating robotic shell removal and precision cut-off into a cohesive automated platform, manufacturers benefit from improved operator safety, increased throughput, greater process consistency, and reduced rework.
About Shape Process Automation
For more than 50 years, Shape Process Automation has provided industrial automation solutions that address efficiency, productivity, and safety challenges within manufacturing operations. As a globally recognized integrator of robotic systems, SPA offers solutions for material handling and assembly applications as well as advanced materials cutting with robotic laser, router, knife, and waterjet processes. SPA proudly serves leading industrial manufacturers within the automotive, aerospace, general industry, logistics, and consumer industries.
About Acme Manufacturing
Acme Manufacturing is an engineering-driven leader in the design and build of custom automated finishing systems. Founded in 1910, the company remains family owned and operated through four generations of the Carlson family and has delivered a steady legacy of innovation across more than 20 industries worldwide. Recognized as a premier FANUC robotics systems integrator in surface finishing and material removal, Acme designs and builds turnkey robotic systems for grinding, polishing, buffing, deburring, and cut-off. Acme also offers a proven line of coated abrasive belt precision centerless grinding systems.
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