Why Badger Alloys world-class castings delivered

“World-class castings delivered” has been our commitment to customers for more than 50 years. A full-service sand casting manufacturer with single-source accountability for the entire casting process – from pattern to finish – Badger Alloys can meet your needs for simple to heavily cored, complex sand castings.

Our full-service sand casting manufacturing campus includes a foundry, machine shop, pattern facility, engineering team, and rapid response technologies. This on-site collaboration throughout the entire process ensures you the highest quality sand castings.

Sand Casting

Equipped to meet your demands for castings from 10 – 4000+ pounds…in 200+ alloys.

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Rapid Response Technologies

Go from CAD to finished casting in expeditied timelines with our robotic patternless molding, 3D-printing and other additive/subtractive processes.

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Pattern Making

Skilled pattern makers create custom wood, polyurethane or metal patterns to your specifications.

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Casting Machining

Cutting-edge equipment and certified machinists meet your tightest tolerance requirements for keyway cutting, milling, dynamic balancing, and turning up to 10,000 lbs.

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Engineering

Our team works collaboratively with customers, foundry and pattern makers to achieve your desired casting result through reverse engineering, solidification analysis, 3D scanning, etc.

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200+ Alloys Poured

Use our interactive tool to compare properties and find your ideal material.

Featured castings

Industries/Specialties

Badger Alloys specializes in creating precision pump and valve components and impellers for a variety of industries. Our customers include some of the most successful companies in North America and beyond, ranging from Fortune 500 companies to small family-owned businesses.

Latest News

Important information on castings, industry trends and what’s happening at Badger Alloys.

Badger Alloys Appoints New Sales Engineer

Nick Hanson, Sales Engineer, Badger Alloys MILWAUKEE, WIS — Badger Alloys, Inc., a full-service castings manufacturer in Milwaukee, Wisconsin, is pleased to announce that Nicholas Hanson has been appointed Sales Engineer. In this role, he will build and manage customer…

Foundry 101: Pattern Making – Tooling Method Selection and Innovations

Badger Alloys Offers Traditional and Next-Generation Pattern Making for Sand Castings Pattern making is a critical component in the casting manufacturing process, serving as the blueprint for casting metal parts. The selection of tooling methods and the evolution of pattern-making…

CASE STUDY: Sapphire Technologies

BADGER ALLOYS CASE STUDY: Sapphire Technologies’ Turboexpander “It’s not easy to find a partner in the sand-casting space that can support prototyping and transition to production volumes for the relatively larger castings we need. Badger Alloys was able to leverage…

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