Known globally for its high-performance recreational vehicles, including Ski-Doo, Can-Am, and Rotax, BRP’s Spruce Pine, North Carolina, facility is more than a production site; it’s a fully integrated, world-class casting operation that specializes in complex, mid- to high-volume aluminum components. 

Among its latest achievements is the I3 Shadow Exhaust, a marine casting that earned honorable mention in the 2025 AFS/Casting Source Casting of the Year Competition for “excellent execution of a lost foam casting.” The casting received the second-highest score in the All-Around Winner category.

BRP US Inc. is the American subsidiary of BRP (Bombardier Recreational Products) Inc., which is based in Canada.

Designed for Complexity

BRP US’s facility in Spruce Pine, North Carolina, keeps every step of its lost foam casting operations under one roof, according to Adam Green, a process engineer for the AFS Corporate Member. From bead expansion and foam molding to casting, machining, and leak testing, the facility is vertically integrated to ensure precision, consistency, and control.

“We’re one of the very few lost foam facilities that I know of where the entire process is encompassed in one building,” Green said. “We expand our own bead, mold our own foam, do the coating, casting, heat treat, machining, leak testing—it’s all done here.”
This end-to-end capability allows the team to maintain tight tolerances, optimize quality at every stage, and respond quickly to design or production challenges. It also fosters a culture of ownership and innovation, where engineers and operators collaborate closely to refine processes and push boundaries.

Curtis Taylor, the facility’s site leader, emphasized the facility’s reputation for excellence. “We get a lot of feedback from customers who’ve visited other casting facilities,” he said. “They consistently tell us this is a world-class operation—not just in cleanliness and organization, but in the systems and processes we use to ensure quality.”

Introducing the I3 Shadow Exhaust

The I3 Shadow Exhaust is a water-cooled exhaust manifold system with an integrated 90-degree gearbox, designed specifically for BRP’s stealth engine platform. Unlike traditional outboard motors that protrude vertically from the back of a boat, the stealth engine is mounted horizontally and sits below deck level. This configuration frees up valuable space on pontoon boats and fishing crafts, enhancing usability.

“Traditional outboards stick up vertically behind the boat,” Green explained. “This one is oriented horizontally, allowing half of it to sit below the waterline. That gives you an extra three to four feet of deck space.”

The stealth engine’s design demanded a casting that could handle complexity. The process includes seven individual foam sections, internal cooling passages, and a 120–lb. pour. Its wall thickness—4 to 5 millimeters—is typical for lost foam castings, but the overall end product reflects the precision BRP achieves with the process.

“You could theoretically make it in another process,” Green said “but it wouldn’t be one piece.”

Any other process would require bolts and seals between parts, and that could sacrifice some integrity in the finished product, as well, Taylor added. And it reduces the overall cost.

Unlike many castings that are adapted to lost foam, the I3 Shadow Exhaust was designed from the ground up for the process. This intentionality allowed BRP’s engineers to fully leverage the advantages of lost foam: complex geometry, reduced weight, and fewer assembly steps.

“That particular part is very representative of the complexity that we can achieve inside of Spruce Pine,” Taylor said, which is why it was selected for submission to the Casting of the Year competition. “The complexity of the part, the design, and the application within the lost foam process, it highlights what we do best.”

From Bead to Boat: The I3 Shadow Exhaust Casting Process

If the I3 Shadow Exhaust represents BRP US’s design ingenuity, the process behind it is a masterclass in precision manufacturing. Every step—from bead expansion to leak testing—is executed with care, control, and a deep understanding of the lost foam method. It’s not just about making a part; it’s about crafting a solution that meets the demands of modern marine engineering.
And because everything is done in-house, including expanding their own polystyrene bead, the team can maintain tight control over every variable. 

So how is the I3 Shadow Exhaust made? Green provided a step-by-step guide of the process:

1.    Bead Expansion and Aging

The process starts with expanding raw polystyrene bead. Once expanded, the bead is aged to stabilize it before molding. This step is critical; dimensional consistency here sets the tone for the entire casting.

2.    Foam Molding and Assembly

The aged bead is then molded into seven individual foam sections. Once molded, the sections are dried to remove moisture and ensure dimensional stability. After that, the sections are glued together in a six-station process to form the complete foam pattern.

3.    Gating System Integration

The assembled foam part is attached to a gating system, forming what BRP calls a “cluster.” This system controls how molten metal flows into the mold during casting.

4.    Refractory Coating

The cluster is robotically dipped into a refractory coating. This coating helps preserve the foam’s shape during casting and ensures a clean surface finish. Viscosity and other parameters are closely monitored to maintain consistency.

5.    Casting and Cooling

Once dried, the coated cluster is taken to the casting line, placed into a flask, and surrounded by compacted sand. Molten aluminum is poured in, vaporizing the foam and filling the cavity. After cooling, the casting is quenched and degated.

6.    Heat Treatment and Cleaning

The casting undergoes heat treatment to achieve the desired mechanical properties. It is then cleaned using shot blast cleaning to remove residual sand and prepare it for machining.

7.    Machining and Leak Testing

The part is machined in two operations using CNC equipment. After machining, it undergoes an air-based leak test to validate the integrity of the internal cooling passages.

8.    Final Inspection and Shipping

Once the part passes inspection, it’s packed and shipped to BRP’s sister facility for final assembly onto the stealth engine platform.

The finished product rings in at 44 lbs. and has three separate chambers for exhaust, water, and gear oil.

A Culture of Precision

BRP’s commitment to quality is evident in every step of the process. The Spruce Pine facility, which began production in the mid-1980s, is ISO-9001 certified, and its quality system is fully electronic, providing traceability from bead expansion to final inspection. 

That level of control also enables rapid iteration and continuous improvement. Engineers can test new designs, tweak process parameters, and implement changes quickly without disrupting production.

Steven Robinson, the facility’s engineering manager, recalled that the overall “driving force behind the operation was to build engine blocks that could meet the complex design needs with the simplest casting method.”

That goal is evident in every piece that comes out of the plant.

The People Behind the Process

Behind every complex casting at BRP US is a team of people who are as invested in the process as they are in the product. The I3 Shadow Exhaust is not just a technical achievement; it’s the result of years of experience, curiosity, and a shared commitment to excellence.

Robinson, who’s been with BRP since 1996, started his career as a high school intern at a sister facility. He moved to the Spruce Pine plant in 2001 to learn more about the casting process and the value of the integrated approach.

“I had the opportunity to be involved in some truly unique production processes and was intrigued to stay because of the different opportunities here,” he said.

Green’s journey is equally rooted in curiosity. He joined BRP 11 years ago, initially drawn by the facility’s proximity to home. But it was the uniqueness of the lost foam process that kept him there and propelled him into engineering.

“I love what we do,” Green said. “It’s fascinating, and I think we’re the best at it. Every day is a chance to learn something new.”
Taylor, who joined BRP two decades ago as an industrial engineer, now leads the site. His perspective is shaped by years of hands-on experience across operations, quality, and leadership roles.

He’s also leading the organization, with 62 employees, on a path of expansion, as they look to diversify production and bring in more third-party business to further capitalize on their capabilities. 

“We’re very proud of what we’ve built here in North Carolina,” Taylor said. “Now we’re looking for ways to build on that.”

A Facility Built for the Future

Built in 1984 and operational since 1986, the plant has continually evolved to meet the demands of modern manufacturing. Today, it stands as a model of vertical integration and process control.

The facility’s layout and workflow are designed for efficiency and scalability. Whether it’s expanding bead, molding foam, or machining castings, each step is optimized for throughput and repeatability. And because everything happens under one roof, BRP can respond quickly to customer needs and market changes.

Over the past several years, the company has also added several new foam presses and upgraded much of the equipment throughout the facility. It’s also been a supporter of AFS-sponsored research related to the potential for 3D printed tooling and patterns.

The evolution is also evident in the type of customers being served there. The facility is currently ramping up production for a major automotive customer with 14,500 parts per month scheduled for delivery starting in December. Additional projects are in development across rail, construction, and even Department of Defense sectors.

“We’re in a steep growth mode,” Taylor said. “We’re diversifying our capacity and bringing in new business. It’s an exciting time.”
That growth is supported by a team that thrives on challenge. Whether it’s developing a new casting, refining a process, or onboarding a new customer, BRP’s engineers and operators are ready to deliver.

BRP, as a whole, is also positioning itself for a low-carbon future. According to an October investor presentation, the company aims to have all of its facilities carbon neutral by 2030 and to achieve zero waste to landfills through innovating the manufacturing processes.

A Symbol of What’s Possible

In many ways, the I3 Shadow Exhaust is more than a casting; it’s a symbol of what’s possible when design, process, and purpose align. It reflects BRP’s commitment to complexity, its mastery of lost foam, and its vision for the future.

“This part really highlights what we can do,” Green said. “It’s complex, precise, and built entirely in-house. That’s what makes it special.”

As BRP US continues to grow and evolve, the I3 Shadow Exhaust stands as a reminder of the power of integration, innovation, and craftsmanship. In Spruce Pine, casting isn’t just a process; it’s a pursuit of excellence.