Aircraft Foundry Co., Inc. is a family-owned and operated sand casting facility founded in 1938. Specializing in high-grade commercial aluminum sand castings, they guide customers from concept to full production. They focus on reducing machining costs by producing optimal sand castings and work with Solidworks, PDF, and Adobe files.
Need a specific city or state? Want to email them directly?
Search, get contacts, and send outreach — all in one place.
Sand Casting Foundries
Last updated: January 2026
This directory lists 98 sand casting foundries across the United States, from job shops to vertically integrated manufacturers.
Buyers typically engage sand casting foundries to solve challenges related to producing large, complex geometries with specific mechanical properties, often at medium to high volumes where other casting methods become cost-prohibitive. The ability to manage material flow and prevent common issues like `shrinkage porosity`, `gas inclusions`, and `hot tears` is crucial, demanding foundries with sophisticated `gating system` design and melt control expertise.
The landscape of sand casting suppliers is diverse, ranging from small, agile job shops specializing in niche non-ferrous alloys like aluminum or bronze for prototyping and short runs, to large, integrated operations pouring thousands of tons of ferrous materials such as ductile iron or gray iron. These larger foundries often offer extensive in-house capabilities like machining, heat treatment, and Non-Destructive Testing (NDT), providing a single-source solution.
Effective collaboration begins with the buyer providing comprehensive 3D models, precise material specifications including required mechanical properties, clarity on critical dimensions, and annual volume forecasts. Foundries, in turn, expect detailed discussions on surface finish requirements and any specific `shakeout` and finishing processes, often leveraging `solidification modeling` to optimize pattern design from the outset.
A significant trend in this category is the increasing adoption of automation in mold making and `molding media` preparation, alongside advanced simulation software that accurately predicts casting defects before production begins. This shift allows for more complex part designs, tighter tolerances, and a proactive approach to quality control, addressing the ongoing challenges of skilled labor and material efficiency.
Company Directory
98 companies nationwide
Akron Foundry Company produces high-quality aluminum castings, offering Permanent Mold, Low Pressure Permanent Mold, and Squeezer Sand processes. Their Floor Sand Foundry specializes in very large castings, weighing thousands of pounds, alongside smaller components, supporting low, medium, and high-volume production.
Based in Lisbon, OH, ALBCO Foundry and Machine is a non-ferrous foundry specializing in sand castings of brass, bronze, copper, zinc, and aluminum. They also provide ZA12 castings using graphite permanent molds and offer in-house machining. The company is ISO 9001:2015 registered.
Based in Cleveland, OH, Alcon Industries, Inc. is a sand casting foundry. They specialize in expertly crafted products from stainless steel and metal alloys, using green sand and no-bake molds. They support custom designs and volumes, producing items from simple valves to complex engine blocks.
Based in Arroyo Grande, CA, Align Manufacturing provides comprehensive sand casting solutions across the United States, Vietnam, India, and Thailand. They specialize in manufacturing custom machined castings using materials like grey iron, ductile iron, stainless steel, aluminum, and carbon steel, catering to both precision components and large-scale applications.
Based in Los Angeles, Alphacast Foundry Inc specializes in high-quality aluminum, cast iron, bronze, and brass castings. They offer Sand & Lost Wax Castings, serving the North American market for over 33 years. The company leverages deep industry knowledge and a commitment to precision for diverse casting needs.
Based in Galesburg, IL, Aluminum Castings Company LLC specializes in high-quality aluminum sand castings. Established in 1964, the company produces both cored and uncored parts in various aluminum alloys, handling projects from prototypes to high-volume manufacturing. They are QMS Certified to ISO 9001:2015 and PED 2014.
Based in Marion, Indiana, Atlas Foundry specializes in Class 25, 30, and 35 gray iron castings, produced using Disamatic Molding Machines. They serve diverse markets including trucking, agriculture, construction, and marine. The company offers support services such as pattern development, metal testing, machining, coating, and heat treating.
Bremer Manufacturing Company, Inc. provides high-quality aluminum castings, offering services from sand casting design to finishing and delivery. Based in Elkhart Lake, WI, the company serves automotive, diesel, EV, marine, and lighting industries, utilizing heat-treating and CNC machining capabilities for precise components.
Brost Foundry Company, with three locations, specializes in sand casting for aluminum, copper, brass, and bronze. They produce castings from one to thousands, up to 350 pounds with 60″ square flask sizes. Capabilities include diverse core types and rapid prototyping options.
Based in Buffalo, NY, Buffalo Metal Casting Co., Inc. specializes in creating aluminum sand cast parts. They perform every part of their process in-house, ensuring quality and control. The company offers single-source reliability, providing comprehensive casting and machining capabilities with value-added services.
Based in Dolton, IL, Calumet Brass Foundry specializes in durable and precise sand castings, offering 24-hour turnaround for emergency copper-based and aluminum needs. Their team produces castings up to 3,550 lbs total mold weight. They provide custom patterns, machining, and pour metals like red brass, aluminum, and various bronzes.
California Casting, Inc., based in Richmond, CA, specializes in creating high-quality aluminum, bronze, and brass sand castings. This family-owned foundry has been operating since 1968, serving military, aerospace, automotive, marine, and medical industries with its capabilities.
Based in Dallas, TX, Calmet provides a range of casting and precision-machined components. They specialize in sand casting, investment casting, permanent mold casting, and die casting. Calmet works with materials such as iron, steel, aluminum, and brass, serving diverse industries including aerospace, automotive, energy, and heavy equipment.
Based in Birdsboro, PA, Cast Rite Metal Company specializes in high-quality aluminum sand castings, producing parts from ounces to 300 pounds. They offer diversified molding, an on-site pattern repair shop, and turnkey secondary operations. The company maintains MIL-I-STANDARD-45208 quality control, emphasizing efficient manufacturing and reliable delivery.
Based in Peoria, IL, Cast Technologies operates as a significant aluminum sand foundry. The company also specializes in brass and bronze sand casting, serving various industries with their expertise in metallic component production.
Based in Baltic, OH, Clark Casting LLC provides custom aluminum sand castings to clients across Ohio and the Midwest. They serve a range of industries, including agriculture, furniture, lighting & electric, and buggy & carriage, handling both small-batch production and large orders.
Cast Metals Technology provides full-service aluminum casting and machining, specializing in low and high-volume aluminum sand castings. The company offers turn-key solutions from concept to final machining, including tooling and solidification analysis. They also provide value-added services such as powder coating and anodizing.
Based in Menlo Park, CA, Control Plastics offers diverse metal casting services, including high-pressure aluminum and zinc die casting. They provide gravity, centrifugal, and investment casting for various metals. Crucially, they perform sand casting for both ferrous and non-ferrous materials, serving automotive, aerospace, and medical industries.
Based in El Cajon, CA, Decco Castings provides precision aluminum sand and permanent mold castings for aerospace and commercial industries. They offer castings from semi-raw to finished machined and painted parts. The company pours various alloys, including 356, A356, and C355, meeting industry specifications such as ASTM B26, ASTM B108, and AMS-A-21180.
DEECO Metals, a custom sand casting supplier, provides high-quality machined castings from its state-of-the-art foundry. In business since 1987, they produce parts ranging from ounces to thousands of pounds, accommodating simple to complex geometries. They serve diverse industrial and architectural applications.
Based in Houston, TX, Dee Foundries specializes in providing non-ferrous aluminum and bronze castings. They utilize the Green Sand Casting Process for parts ranging from ounces to 100 lbs. Dee Foundries produces castings in numerous alloys to ASTM specifications and offers heat treatment services.
Based in Denison, TX, Denison Industries offers machined aluminum castings and sand casting foundry services. Their AS 9100 D & ISO 9001:2015 certified facility supports aerospace, automotive, commercial, and military/defense sectors. They provide complex components using advanced production technology.
Based in San Jacinto, CA, Edelbrock Foundries specializes in state-of-the-art green sand metal casting for aluminum products. They offer comprehensive services including core production, pattern making, heat treating, engineering, and machining. The company provides quality, American-made value for diverse manufacturing needs.
Based in Cincinnati, OH, Epcor Foundry specializes in aluminum sand casting and prototyping services. The company produces industrial components and high-performance parts, focusing on repeatability and quality in every casting for various applications.
Based in Cincinnati, Ohio, Chris Erhart Foundry and Machine Co. is a jobbing foundry specializing in low to medium volumes of gray iron and ductile iron castings. They produce castings ranging from 1 pound to 7000 pounds, offering full-service support from initial design through to final shipping.
Farrar Corporation offers ductile iron sand castings and precision-machined components. Their vertically integrated, ISO 9001:2015-certified facilities provide in-house pattern design, casting, heat treating, and machining. They produce 5 to 75 pound ductile iron castings for mid- to high-volume programs.
Based in Cleveland, OH, Ferralloy, Inc. specializes in sand casting, producing parts from a wide variety of ferrous and non-ferrous alloys. They offer both rough and finish-machined castings, utilizing green sand and no-bake molds. Serving global industries, typical applications include impellers, valve, and pump components, managing high-volume production.
Based in Coolidge, TX, Frazier & Frazier Industries, Inc. is an ISO 9001:2015 registered gray and ductile iron foundry. Established in 1972, the company provides turn-key casting solutions with a capacity up to 150 tons per day. They serve OEM customers across various industries.
Based in Grand Prairie, TX, Firstex Industries, Inc. provides metal casting and forging services. Specializing in sand casting for large components over 150 lbs, the company also offers investment casting and die casting. They manage quality and delivery using Pacific Rim manufacturing resources.
Founded in 1957, employee-owned Fisher Cast Steel provides sand and investment casting services for stainless, nickel-based, and carbon steel alloys. Their foundry produces castings weighing 0-8,500 lbs, utilizing engineering with solidification and CAD software. The ISO 9001:2015 certified company serves industries including pump & valve, power generation, aerospace, and industrial equipment.
Based in Russia, OH, Francis Manufacturing Company provides quality aluminum sand castings. They offer design assistance from concept to completion, producing castings from fractions of an ounce to several hundred pounds. Serving a variety of industries and accounts coast to coast, the company emphasizes strong customer relationships and timely delivery.
Based in Fort Worth, TX, Fort Worth Aluminum Foundry, Inc. custom manufactures large and small aluminum sand castings. They utilize no-bake and green sand foundry processes, producing parts up to 1,000 pounds. Services include machining, anodizing, and heat treating, catering to industries like jewelry, pneumatic conveying, and satellite antenna systems.
Based in San Leandro, CA, General Foundry Service specializes in custom aluminum and zinc-aluminum cast parts. They offer five complementary casting processes, CNC machining, and surface finishing, including plating and painting. The company provides turnkey solutions for prototype, low, and intermediate volume finished castings with tight tolerances.
Based in South Gate, CA, H&M Foundry Inc. specializes in sand casting services, suitable for single pieces and small batch production. Established in 1980, the company also offers aluminum casting capabilities. H&M Foundry is committed to fostering long-term client relationships through its direct manufacturing services.
Based in Camarillo, CA, Laube Technology provides green sand casting services, offering a versatile and cost-effective solution for producing metal parts. They specialize in manufacturing parts with intricate designs and consistent quality. Established in 1948, the company also handles other metal and electronic products.
Based in Galena, IL, Lemfco, Inc. specializes in manufacturing small to medium runs of gray iron castings. They utilize automatic green sand molding machines and induction furnaces to produce castings ranging from ounces to 100 pounds. Industries served include natural gas, agriculture, municipal, automotive, and hydraulics. They offer tooling, pattern storage, and finishing services.
Based in Delaware, Ohio, Liberty Casting Company provides American-made gray and ductile iron castings. It operates two vertically integrated facilities, offering large iron casting with a daily melt of 90 tons and automated casting for components up to 500 pounds. The company serves various industries with a strong focus on quality.
Based in Avon, OH, Lite Metals Company is a magnesium and aluminum foundry. They produce sand castings and have over 170 years of experience in the foundry business, operating since 1844.
LS Manufacturing provides professional sand casting services, specializing in large, complex metal components for industrial applications. They offer cost-effective solutions for parts requiring high strength and durability, with typical tolerances from ±0.5 mm to ±2 mm. The company processes a wide range of metals and is ISO 9001 certified.
Based in Ontario, California, Lynwood Pattern Service, Inc. is an aluminum foundry specializing in sand and permanent mold castings. They serve commercial, high performance automotive, defense, and aerospace industries, utilizing processes like dry sand no-bake, green sand, and shell cores.
Based in Fort Worth, TX, Midland Manufacturing Company is a 136-year-old brass, bronze, and aluminum foundry. They specialize in high-quality sand castings, employing automatic green sand molding, no-bake, shell, and cold-box core methods. The facility, with a daily capacity up to 70,000 lbs, complies with ISO and Mil-Spec standards.
Midwest Metal Products in Winona, MN, offers metal casting services with decades of foundry experience. They provide engineered castings, often utilizing sand, metal, or ceramic molds. A dedicated metallurgist ensures material selection and quality for complex parts, serving industries like mining and oil and gas.
Based in Terre Haute, IN, Modern Aluminum Castings Co., Inc. provides comprehensive metal casting services. They specialize in aluminum sand castings, including airset/nobake processes. The company also offers aluminum permanent mold castings, aluminum die castings, and ductile/grey iron castings for various industrial clients.
Morris Bean & Company is an aluminum foundry specializing in sand-molding techniques, including proprietary Antioch plaster and nobake sand methods. They produce castings of various shapes and sizes, capable of very thin parts. The company holds ISO9001:2015 certification, utilizing MAGMASOFT® casting simulation, non-destructive testing, X-ray, and CMM for quality assurance.
Based in Corsicana, TX, Oil City Iron Works, Inc. is an American foundry, pattern-maker, and CNC machine shop. Established in 1886, the company specializes in gray and ductile iron castings, offering comprehensive manufacturing solutions from prototyping to production. They maintain a rejection rate of less than 1% annually.
Based in Richmond, VA, OK Foundry makes gray and ductile iron sand castings. They produce parts ranging from 1 lb. to 400 lbs. using cope and drag phenolic urethane bonded sand molding, also known as no-bake casting.
Based in Loves Park, IL, Olson Aluminum Castings operates as a custom sand cast foundry. The ISO 9001:2015 registered company produces industrial-grade, pressure-tight, and leak-free castings with superior machining properties and surface finishes. They are known for offering some of the shortest production lead times for challenging projects.
Based in Eugene, OR, Oregon Pattern & Foundry specializes in manufacturing high-quality aluminum and bronze sand castings. The company also provides comprehensive machining, rapid prototyping, and pattern-making services, catering to various industrial needs.
Based in Ontario, California, Performance Aluminum Products provides high-quality sand-cast aluminum components. This aluminum foundry offers raw casting services, new product development support from drawings or samples, and finishing services including drilling, tapping, machining, and various coatings. They also combine cast and machined parts.
Based in Mound House, NV, Production Pattern & Foundry is a full-production casting foundry. They specialize in aluminum alloys, pouring high-quality castings via greensand and permanent mold processes. The company is certified to ISO 9001:2015, IATF 16949, and ISO 14001:2015 standards, ensuring robust quality management.
Precise Cast specializes in quality aluminum and magnesium sand casting. This long-standing company provides manufacturing services for robust and precise metal parts. It maintains an A+ rating with the Better Business Bureau, demonstrating a commitment to customer satisfaction and operational excellence within the foundry industry.
Based in Somonauk, IL, Precision Enterprises is an aluminum sand casting foundry providing machined castings using various materials and alloys. With over 70 years of experience, the company operates modern, automated facilities and multiple CNC machining centers. They specialize in highly complex, cosmetic castings, offering extensive engineering expertise and one-stop solutions.
Based in Commerce City, CO, Protocast Inc. specializes in sand casting services, utilizing both traditional green sand and contemporary air set molds. The company offers precision and printed sand casting, creating parts of diverse sizes and complexities for various industries. They are ISO 9001:2015 certified and ITAR registered.
Based in Salem, OH, Quaker City Castings produces high-quality sand and centrifugal castings from steel and iron. They utilize a no-bake molding process for tight tolerances and offer CNC machining. Specializing in complex, high-performance parts up to 3,500 lbs, they serve demanding industries like oil & gas and defense.
Based in City of Industry, CA, Reuland Aluminum Castings is an aluminum foundry specializing in green sand, permanent mold, and no-bake sand casting processes. The company provides complete casting solutions, including pattern making, heat treating, machining, and assembly, serving aerospace, industrial, automotive, and medical industries.
Seneca Foundry provides green sand casting services for intricate iron castings and metal components. Based in Webster City, Iowa, the company has over a century of experience in this manufacturing process, offering cost-effective and versatile solutions. They produce a range of products, from industrial equipment parts to artistic sculptures.
Based in Milwaukee, WI, Stainless Foundry & Engineering delivers quality sand castings using over 250 different alloys. Capabilities include core making, air-set molding techniques with flask sizes up to 72″ x 72″, and melting up to 2800 lbs. The company focuses on short lead times.
Based in Rockdale, TX, Texaloy Foundry specializes in custom sand castings for high-wear and corrosion-resistant alloy components. They produce parts ranging from one pound to 5,000 pounds, pouring specialized materials like Ni-Hard and High Chromium Iron. Texaloy serves industries requiring robust metal components.
Texas Aluminum Foundry is a family-owned and operated facility, providing aluminum sand casting services since 1946. They offer superior aluminum castings, supported by design services, 3D CAD modeling, and rapid prototyping. Capabilities include utilizing 3D printed plastic models and sand molds for quality production.
Based in Cuyahoga Heights, OH, Thompson Aluminum Casting Company is a foundry producing premium aluminum and magnesium castings. They utilize both sand and permanent mold methods for critical engine and structural components. The company primarily serves the Aerospace and Defense industries and is Nadcap, ISO 9001, and AS 9100 certified.
TPi Arcade specializes in advanced Aluminum V-Process sand casting, producing smoother, thinner-walled parts with tighter tolerances and no draft angles. This process uses fine, dry sand without binders, held by vacuum. They offer prototypes, low-volume production, raw castings, and turnkey programs with fast turnaround.
Based in Niles, OH, Trumbull Foundry produces high-quality custom castings from gray and ductile iron. They also work with carbon, stainless, and tool steels, offering innovative solutions for various industries across the U.S. Trumbull Foundry provides rapid prototyping services for efficient project development.
Based in Sugar Land, TX, Unique Industrial Product Co. provides Sand Casting services, alongside Die, Gravity, and Investment Casting. They engineer custom parts from a range of materials including Aluminum, Zinc, Copper, Magnesium, and various steels, offering additional value-added services like machining and assembly.
Based in Entiat, WA, US Aluminum Castings is a precision aluminum casting supplier and full-service foundry. They offer multiple casting processes, in-house heat treatment, machining, powder coating, and non-destructive testing. The company serves defense, aerospace, heavy truck, marine, and commercial applications.
Wabash Castings is an aluminum foundry that specializes in manufacturing aluminum sand casting parts. The company focuses on providing precision components, delivering parts on time and on budget for clients requiring high-quality aluminum castings.
Wisconsin Aluminum Foundry, based in Manitowoc, WI, is a non-ferrous casting company specializing in aluminum, bronze, and brass. They provide green sand casting, air set sand casting, and permanent mold casting processes. Operating since 1909, WAF serves manufacturers with rigorous requirements across various industries.
Based in Waukesha, WI, Waukesha Foundry Inc. provides full-service design, engineering, and casting capabilities. They specialize in manufacturing processes including tooling casting, no-bake sand molding, and investment casting through Foamcast and PMMA methods.
Based in Roseville, MI, Warner Brothers Foundry Company specializes in sand casting services, including aluminum sand castings and no-bake sand molding. They guarantee 100% US-manufactured aluminum parts and tooling, emphasizing quick project turnaround. The company works with various non-ferrous alloys like specific grades of aluminum, brass, and bronze.
Wichita Falls Manufacturing, Inc., located in Wichita Falls, TX, provides comprehensive foundry services, including investment casting, sand shell, and permanent molding. They cast various metals such as aluminum, stainless steels, brass, bronze, and carbon/alloy steels. The company also offers full-service machining and custom mold building.
Foundrion Group specializes in comprehensive sand and metal casting services. Capabilities include in-house pattern creation, 3D scanning and printing, rapid prototyping, and reverse engineering. They provide advanced material testing, X-ray, NDT, machining, heat treating, and impregnation to ensure casting integrity for clients worldwide.
ID Castings manufactures iron castings from two Indiana and Illinois locations, leveraging over a century of experience. They produce parts weighing 50 to 4,000 pounds, accommodating large production volumes and smaller orders. The company focuses on precision, quality, and customer relationships.
Based in Dallas, TX, A & B Foundry LLC specializes in custom metal casting services for aluminum and brass. With over 50 years of experience since 1965, they cast a wide variety of products in large and small lot sizes for businesses and contractor professionals, including drains, skimmers, and anchors.
Based in Peoria, IL, Alcast Company provides high-quality green sand and air-set (no-bake) aluminum castings. They offer custom-engineered casting solutions for industries including automotive, aerospace, agriculture, performance, and industrial manufacturing. The company also produces low-pressure permanent mold aluminum castings.
Based in Ontario, CA, Alumistar Inc. is an aluminum foundry specializing in high-quality sand-cast aluminum components. They produce parts to client specifications using premium aluminum ingots. Services include raw casting, new product development support from drawings, and finishing for cast and machined aluminum parts.
Based in Milwaukee, WI, Badger Alloys is a full-service sand casting manufacturer, family-owned for over 50 years. They offer single-source accountability for the entire casting process, from pattern to finish. Pouring over 200 alloys, they leverage additive and subtractive manufacturing to produce high-quality, complex castings efficiently.
Based in Stevens, PA, Boose Aluminum Foundry has been providing American-made quality aluminum sand castings since 1933. The company serves a range of sectors, including military, medical, robotics, and power generation, along with various private and commercial industries. It focuses on dependable supply of quality castings.
Based in Jacksboro, TN, Clinch River Casting, Inc. operates as a 100% No Bake Sand Foundry. They utilize flaskless molding and No Bake core processes for quick setups and minimal tooling costs. Specializing in short run orders with short lead times, they cast Ni-hard, Gray, and Ductile Iron Alloys.
Based in Cudahy, CA, Consolidated Precision Products (CPP) operates a sand and permanent mold foundry. The company specializes in producing complex aluminum castings, primarily serving the demanding aerospace and defense industries with precision components.
Based in Eastland, TX, EBAA Iron, Inc. operates its own Texas-based ductile iron foundries. The company casts and assembles MEGALUG® Joint Restraint and other restraint products, specializing in components for water pipeline applications.
Based in Erie, PA, Erie Bronze and Aluminum Co specializes in sand casting bronze, aluminum, steel, and iron. The company provides a range of castings, including cylindrical aluminum castings and glass container moulds, serving various industries with their comprehensive manufacturing capabilities.
Based in Bettendorf, Iowa, LeClaire Manufacturing Co provides comprehensive aluminum sand casting and permanent mold casting services. They cast and machine simple to complex aluminum parts. The company leverages automation in its manufacturing processes to deliver consistent, high-quality, and on-time aluminum sand castings and machined components.
Mabry Iron Castings is a modern gray and ductile iron foundry located in the Texas Gulf Coast Region. They utilize automated green sand, air set, and no bake molding for gray and ductile iron castings from 1 lb. to 4,000 lbs. Serving diverse sectors like Oil & Gas, Power Generation, and Agriculture, the company also provides value-added services.
Ohio Aluminum Industries, Inc. produces complex aluminum castings utilizing dry sand, green sand, and permanent mold processes. The company provides components for the aerospace, automotive, commercial/trucking, and defense industries.
OSCO Industries specializes in high-volume, small to medium green sand and shell molding techniques. The company excels at producing a range of cast gray iron parts, offering robust casting solutions for various industrial applications and demanding specifications.
Based in Franklin, NH, Patriot Foundry & Castings specializes in high-quality nonferrous sand castings. They utilize state-of-the-art capabilities and lean production methods to deliver dimensionally accurate, repeatable, and consistent parts. With over 20 years of experience, the company partners with clients to solve part development and manufacturing challenges.
Based in Lufkin, TX, PumpWorks Castings provides sand casting services for production needs of almost any scale. They utilize a standard sand casting process for various molten materials. The company's quality assurance includes physical property testing, live casting X-ray analysis, certified spectroanalysis, and non-destructive testing techniques.
Based in Orrville, OH, Quality Castings Company has been producing gray and ductile iron castings since 1933. This foundry specializes in both high-volume and short-run production. The company is ISO 9001:2015 certified, providing quality iron casting services with a focus on consistency and precision in its manufacturing.
Based in Richmond, VA, Richmond Iron specializes in historic reproductions using direct sand molding. The company directly molds from original castings to replicate historic cast iron pieces, catering to preservation and restoration needs.
Ross Aluminum is a custom Aluminum Casting Foundry based in Sidney, OH, specializing in both dry and green sand, as well as permanent mold castings. They serve industries like aerospace, automotive, defense, heavy truck, and small engine, offering solutions for complex shapes and various casting sizes.
Based in Longview, TX, Southwest Steel Casting is a woman-owned minority business founded in 1971. The company produces steel castings for various industries and applications, handling items up to 6,000 lbs. It operates a 150,000 sq ft production facility.
Based in Windsor, CT, The Taylor & Fenn Company provides ferrous sand casting services for iron and steel components. Operating since 1834, they produce custom-designed, low-volume castings ranging from one pound to over 6,000 pounds. The company utilizes both green sand and chemically bonded sand, serving diverse industries.
Based in Wichita Falls, TX, Taylor Foundry Company manufactures gray iron castings. Serving diverse sectors such as agricultural, industrial, construction, and municipal markets, the company has provided foundry services since 1925. They specialize in producing durable cast iron components for various applications.
Texas Metal Casting specializes in producing aluminum, brass, bronze, and stainless steel castings. They offer sand casting, permanent mold, and no-bake mold processes, along with various core production methods. In-house facilities include pattern making, heat treating, finish machining, and quality control with certified analysis and dye penetration inspection.
Based in Bingham Farms, MI, The Federal Group USA provides custom sand casting services, manufacturing high-quality metal components since 1980. They work with diverse materials like steels, iron, and aluminum for high and medium volume production. The company serves industrial manufacturing, energy, and construction sectors.
FA Foundry specializes in high-quality cast iron production, providing foundry casting services. The company offers efficient mass production utilizing advanced molding systems and delivers cost-effective solutions. Their cast iron products feature superior mechanical properties like high strength, thermal stability, and wear resistance, serving industries such as marine components.
Based in Texas, IPC Foundry specializes in turnkey casting services. They provide comprehensive solutions that include metal finishing work such as stamping and painting, serving various industrial needs.
Based in Vernon, CA, West Coast Foundry, LLC produces custom cast components from a variety of alloys. They specialize in valve and pump components using corrosion-resistant alloys, also offering structural alloys. The company serves OEMs across diverse sectors including marine, aerospace, medical, automotive, and mining.
Found what you're looking for? Unlock 72 emails and 93 phones.
How to Choose a Company
- Verify their experience and metallurgical controls for your specific alloy (e.g., high-strength aluminum A356-T6, or specific grades of ductile iron), scrutinizing their melt deck's ability to maintain precise chemistry and control the inoculation process for proper `graphite morphology` or grain structure.
- Assess their approach to `pattern equipment` and `core box` construction. Ensure they can manage patterns (whether wood, plastic, or metal) suitable for your required annual volumes and dimensional accuracy, including maintenance schedules and storage for tooling longevity.
- For critical components, thoroughly investigate their Non-Destructive Testing (NDT) capabilities. Specifically ask about in-house radiographic inspection (X-ray) for `shrinkage porosity` or `gas inclusions`, magnetic particle inspection for surface defects, and ensure they meet relevant standards like ASTM E186, E446, or E71.
- Scrutinize their dimensional control and typical `as-cast` tolerances. A common red flag is a foundry unwilling to discuss their typical capabilities or how they mitigate distortion and `core shift` after `shakeout`, which can lead to excessive post-casting machining costs or unacceptable scrap rates.
- Be extremely cautious of foundries that offer significantly lower `pattern equipment` costs without clear justification regarding material, expected life cycle, or maintenance protocols. This often signals a compromise on tooling quality that will result in higher per-part costs, increased scrap, and costly delays due to pattern degradation or premature wear.
Supplier Types at a Glance
| Type | Best For | Typical MOQ |
|---|---|---|
| Large Production Foundries | High-volume components (tens of thousands+), complex assemblies requiring secondary services like machining, broad material range (ferrous & non-ferrous). | 500-1,000+ units |
| Specialty Alloy Foundries | Niche material requirements (e.g., specific bronze alloys, high-nickel superalloys), applications with stringent metallurgical controls (e.g., aerospace, defense), often smaller to medium batch sizes. | 50-500 units |
| Job Shop / Low Volume Foundries | Prototyping, small batch production, unique designs, less common alloys, often quicker turnaround for new projects with simpler geometry. `Pattern equipment` is typically wood or plastic. | 1-100 units |
Frequently Asked Questions
What types of pattern equipment are used in sand casting, and how does the choice impact cost and lead time?
Sand casting utilizes various types of pattern equipment, with the choice primarily driven by production volume, dimensional accuracy requirements, and budget. Wood patterns are economical for low-volume runs or prototypes but wear quickly. Plastic (e.g., urethane, epoxy) patterns offer better durability and surface finish for medium volumes. Metal patterns (e.g., aluminum, cast iron) are the most durable, providing the highest accuracy and longest lifespan, making them ideal for high-volume production, though they have the highest upfront cost and longest lead time. The material directly influences tooling cost, lead time for fabrication, and the overall life of the pattern.
How can I ensure consistent metallurgy and mechanical properties for my sand cast parts across production runs?
Ensuring metallurgical consistency requires stringent process control at the foundry. Look for foundries that employ regular spectrographic analysis of each melt to verify alloy chemistry before pouring. They should have robust control over pouring temperatures, inoculation practices (especially for ductile iron to control `graphite morphology`), and cooling rates. Specifying the use of test bars cast concurrently with your parts, and requiring their destructive testing (e.g., tensile strength, hardness), provides objective evidence of consistent mechanical properties.
What `as-cast` tolerances can I realistically expect from sand casting, and how much machining allowance should I specify?
Realistic `as-cast` tolerances for sand casting typically range from ±0.030 inches for small features to ±0.060 inches or more for larger dimensions, with additional considerations for factors like part complexity, alloy type, and `molding media`. Foundries often adhere to standards like ISO 8062 for general casting tolerances. For areas requiring precision, a machining allowance is crucial, typically ranging from 0.125 inches (3mm) for smaller parts to 0.250 inches (6mm) or more for larger components, to ensure enough material to clean up surfaces without exposing `shrinkage porosity` or other subsurface defects during machining.
What are the most common defects in sand castings, and how can they be prevented through design or process?
The most common sand casting defects include `shrinkage porosity` (voids due to insufficient liquid metal during solidification), `gas inclusions` (trapped gas), `hot tears` (cracks forming as the metal shrinks against restraint), and `misruns` (incomplete filling of the mold). These are often prevented through careful design of `risers` (reservoirs of molten metal to feed solidifying areas), `gates` (channels for metal flow), and `chills` (metal inserts to promote localized rapid cooling). Proper `molding media` selection, control of pouring temperature, and effective venting of the mold cavity are also critical process controls.