Pattern Making

Sand Casting Foundry with Advanced Patternmaking Capabilities

“The tool life seems better when we cut castings supplied by Badger Alloys.”

– Buyer, Worldwide Pump Manufacturer     


Our onsite casting pattern facility helps ensure top-notch tooling, including traditional wood or urethane patterns as well as robotically milled sand molds and 3D-printed plastic patterns. Our experienced patternmakers have decades of experience and work closely with our sophisticated Engineering Team to create casting patterns designed to suit your specific requirements:

  • Captive pattern shop collaborates with our sand-casting foundry
  • Precision CNC wood and urethane pattern construction
  • Sand-casting pattern design consultation
  • Experienced journeyman sand casting patternmakers
  • Robotically milled patternless molding using our in-house robot
  • 3D-printed plastic patterns
  • 3D-printed sand molds
  • Engineering changes
  • Engineered mounting, gating & rigging systems
  • On-site protected sand-casting pattern storage

Traditional and Next-Generation Tooling

Learn more about our newly remodeled pattern shop, located on our manufacturing campus in Milwaukee, in this video.

Your First Step to a Quality Casting

Whether your castings are simple or complex, require high volume or low volume usage, we are dedicated to meeting your precise requirements. Our team of patternmakers, engineers, and foundry personnel work collaboratively to achieve your desired result. Sometimes traditional tooling methods will serve your needs best. Other times new technologies like robotic patternless molding may make more sense. We are invested in working with you to explore your options and determine the best solution for your casting process. Download our whitepaper on “Which tooling method makes sense for your sand casting.”

Traditional Wood or Urethane Patterns

At our on-site sand-casting pattern shop, our highly skilled and experienced pattern makers create custom patterns based on your exact specifications. Because our pattern shop is dedicated solely to serving our foundry and customers, you can be assured you will always receive the highest quality patterns.

Our casting pattern makers work closely with our engineering team and foundrymen on every job to ensure we produce the very finest tooling. We don’t take shortcuts in our sand-casting pattern making because we’re accountable for the resulting component. This single-source capability, and vested interest in the entire process, ensures the best castings in the shortest amount of time. The care we put into building each pattern significantly improves the tooling life expectancy.

Our talented craftsmen have many years of experience at Badger Alloys, and understand our process and passion for superior quality castings.

Precision Tooling
Precision Tooling

Robotic Patternless Molding and 3D Technologies

Your casting may require a robotically milled mold or prototype, or a 3D-printed mold. Using robotically milled tooling can:

  • Shorten lead time by up to 70%
  • Decrease upfront investment by up to 30%
  • Eliminate equipment storage and/or maintenance cost
  • Create large castings
    • 8’x8′ maximum mold size
      (cope or drag)
    • Castings up to 4000 lbs.

Regardless of your selected tooling method, we are committed to providing the highest value casting for your project. Download our whitepaper on “Which tooling method makes sense for your sand casting.”

Casting Pattern Storage

After project completion, customers can store patterns at Badger Alloys’ 45,000 square foot pattern storage facility. We know how valuable and important your patterns are, and we keep them protected in our secure building dedicated solely to pattern storage. Keeping active patterns in our facility allows for quicker turnaround and lengthens casting pattern life.

Contact Badger Alloys for more information or quickly request a quote online for our casting pattern making services.


Our team works collaboratively with customers, foundry and pattern makers to achieve your desired casting result.

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Cutting-edge equipment and certified machinists meet your tightest tolerance requirements.

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Rapid Response Technologies

Go from CAD to casting in as little as two weeks with our patternless molding, 3D-printing and other additive/subtractive processes.

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Sand Casting

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

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how can we help?

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