Engineered Castability

Rapid response, lower capital costs and product rejuvenation are critical to business success in today’s world. Through techniques such as additive manufacturing (e.g., 3D printing), subtractive manufacturing (e.g. robotically milled) or more traditional methods, Badger Alloys’ team of experienced foundry engineers can work with you to determine the best process and material for your casting needs. Download our whitepaper on tooling methods.

Our foundry engineering team works collaboratively with our sand foundry and casting pattern making personnel to help customers achieve the desired result. This single-source capability enables Badger Alloys to produce the best quality castings in the most cost-effective manner… with the shortest possible lead time. The use of these next generation manufacturing processes can allow you to move your project from CAD to casting in as little as two weeks.

Our engineers can consult with you to recommend the process that will result in the best finished casting. We start by analyzing casting pattern making methods to determine what makes the most sense for your project based on your lead time, quantity, casting size and other criteria. Whether your casting requires a robotically milled mold, a 3D printed prototype, or a hand-crafted traditional wood or urethane pattern, we are committed to providing the highest value castings.

Engineering Capabilities

Process and materials selection consultation
Casting manufacturability consultation
Rapid response/short run/prototype casting
Advanced technologies, including a KUKA Quantec six-axis robot
Solidification modeling/analysis by MAGMA-trained engineers
3D modeling and printing
Scanning
Reverse engineering
On-site foundry engineering team

Read our article to learn how interactive engineering can improve your castings.

3D Modeling and Solidification Analysis

Additionally, we have the ability to create 3D models using your drawing or models, to help you evaluate the best casting process for your needs. This process allows our engineers to work with you in the digital space to analyze, test and troubleshoot casting dimensions, processes and even materials prior to pouring your casting. This helps ensure you get the best casting the first time.

Read our article to learn more about how solidification analysis can optimize castability of your sand casting.

Reverse Engineering

Leveraging our in-house pattern-making expertise, modern scanning technology, and solidification modeling experience, we are able to re-create your parts in the digital space prior to manufacturing. Not only can this reduce overall production time, it can also reduce total manufacturing cost. Fine tuning your castings digitally improves the accuracy of your completed parts on the first run.

Read our article to learn more about How 3D Scanning can be a Solution for Worn/Obsolete Equipment of Parts.

Prototype Casting

In general the benefits of prototype casting include:

Shorter design cycle
Ability to make design changes/enhancements quickly and cost effectively
Ability to test during tooling production
Reduction of overall time-to-market by up to 90%
Lower up-front capital cost
Reverse engineering

Read our article to learn more about how prototype casting can produce high-quality castings with quick turnaround.

Engineering Team Qualifications

Combined 80 years’ experience in foundry engineering. Our team boasts strength in experience (one of our engineers has been with Badger Alloys for more than 40 years!), as well as strength in education and training in cutting-edge technologies.

Diverse engineering backgrounds. Our foundry engineering team brings deep experience from multiple industries, allowing us to provide varied perspectives and determine the most ideal solution for each project.