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.
“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.
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.