Foundry Lab Secures $8M to Revolutionize Metal Casting with Microwave Technology

A Novel Approach to Metal Casting: Foundry Lab's Microwave Technology

Do you recall the Easy Bake Oven? The process involved combining colored powder with water to create a dough or batter, placing it within a mold, and then baking it until – ding! – a rather unappetizing treat emerged. Foundry Lab, a startup originating from New Zealand and supported by Peter Beck of Rocket Lab, has developed a comparable process. However, instead of utilizing chemicals and a conventional “oven,” they employ metals and microwave technology.

Rapid Metal Part Production

The company officially launched on Monday, announcing an $8 million Series A funding round. According to David Moodie, Foundry’s founder and CEO, they are leveraging “a microwave, but significantly enhanced” to cast metal components at a speed exceeding that of metal 3D printing.

“The system is remarkably user-friendly; operators simply place the mold, introduce the cold metal powder or ingots, activate the microwave, and then step away,” Moodie explained to TechCrunch. “It even signals completion with a ‘ding,’ mirroring the simplicity of heating a microwave dinner.”

Interestingly, Foundry’s microwave has also been used to cook a traditional New Zealand meat pie. The result, achieved in mere seconds, was not particularly palatable, as Moodie noted.

Speed and Efficiency Compared to Traditional Methods

Conventional casting techniques, such as investment casting, 3D printing, and die-casting, typically require between one and six weeks for production. Foundry asserts that it can produce brake shoes for automobiles in under eight hours, utilizing molds created through 3D printing with computer-aided design (CAD) and their specialized microwave.

Currently, the startup is focused on zinc and aluminum, but has successfully tested stainless steel and plans to expand to other metals like copper and brass in the future.

Targeting Automotive R&D and Prototyping

While Foundry’s technology holds potential for broader manufacturing applications where metal 3D printing falls short, its immediate objective is to assist automotive research and development teams. They aim to provide production-identical, functional metal parts for testing and prototyping prior to committing to large-scale manufacturing.

“Some companies we are in discussions with create up to 600 prototype vehicles before a final model is released, necessitating frequent changes and iterations, which can become costly,” Moodie stated, adding that tooling expenses can range from $50,000 to $100,000.

Addressing Limitations of Existing Prototyping Methods

Moodie recounts that prior to establishing Foundry, he operated an industrial design consultancy, designing products for mass production. He encountered frustration as testing authorities frequently rejected applications due to parts being produced by 3D printers or CNC machines, raising concerns about potential structural inconsistencies.

“Driven by this challenge, I embraced the resourceful Kiwi spirit and developed a working system in my workshop,” he said. Much of the initial experimentation occurred during New Zealand’s lockdowns, when access to his usual workshop was restricted, utilizing standard microwaves.

“Our goal is to replicate actual castings, simulating die casting but in a faster and more economical manner. Traditional die casting tooling can take three to six months to fabricate.”

Future Growth and Expansion

Foundry is still in its early stages. Currently, only a limited number of their large-scale microwaves are undergoing trials with prospective customers. The Series A funding – led by Blackbird, alongside GD1, Icehouse, K1W1, Founders Fund, Promus, and WNT Ventures – will be used to prepare for production by the end of 2023.

A portion of the funding will be allocated to expanding the team. The company has experienced rapid growth, increasing from six employees during initial fundraising to 17 full-time staff members. The aim is to reach approximately 35 employees in the coming months, a task complicated by New Zealand’s pandemic-related border restrictions.

“The border closures are now impacting our recruitment efforts,” Moodie noted. “There are only two recognized microwave experts in the country, and both are currently employed. Securing additional expertise is proving challenging, and we are actively seeking qualified individuals to join our team.”

New Zealand's Evolving Landscape and Global Ambitions

New Zealand is gradually easing internal restrictions, with Auckland emerging from lockdown and city borders reopening in mid-December. The country anticipates resuming the invitation of vaccinated travelers starting April 30, 2022, potentially enabling Foundry and other New Zealand startups to recruit talent internationally.

Despite being based in New Zealand, Foundry is targeting markets in the United States and Europe. The company’s long-term vision involves refining the microwave technology to achieve the capacity required for mass production.