Sand Casting Pattern Design

The best components start with a qualified and experienced casting pattern maker.

At our captive sand casting foundry & pattern shop, our highly skilled pattern makers create custom patterns based on your exact specifications.

We can also repair/refurbish your existing sand casting patterns as needed.

Because our casting pattern shop is dedicated solely to serving our foundry and customers, you can rest easy knowing you'll 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 components.

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 the our process and passion for superior quality castings.

Whether your patterns are simple or complex, require high volume or low volume usage, our casting pattern makers are dedicated to meeting your exact requirements.

We can construct your new pattern using wood, plastic or metal.

Casting patterns can be fully CNC machined (with CNC pattern making) or created using traditional methods.

3D Modeling

Additionally, we have the ability to create 3D modeling using your drawing or models.

You can send files to us in virtually any file format, including:

  • IGES files
  • STEP files
  • SCPRT  (surfcam)
  • SLDPRT  (solidworks)
  • PSMODEL  (powershape)
  • DGK   (powermill)
  • DWG (autocad)
  • MCX  (mastercam)
  • Parasolid x_t

Casting Pattern Repair and Engineering Changes

Our craftsmen have the ability to work with older existing pattern equipment and repair or refurbish it as needed for production.

We can also perform any engineering changes needed to modify your pattern equipment for new design requirements.

Regardless of whether we create your new casting pattern or replace an existing one, you'll appreciate our seamless service - from pattern production, to gating and rigging, & into our foundry for casting production.

Reverse Engineering

If you have worn or obsolete castings, we can reverse-engineer the castings to produce replacement patterns.

We can also use this process to modify patterns for existing components.

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.