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 casting in as little as two weeks with our 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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Cutting-edge equipment and certified machinists meet your tightest tolerance requirements.

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

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200+ Alloys Poured

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

Featured castings


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 CEO to Represent Wisconsin Metalcasters at Government Affairs Fly-in in DC

PRESS RELEASE For immediate release June 6, 2024 Contact:  Sara Davis, saradavismarketing@gmail.com, 414.303.5149 Badger Alloys CEO to Represent Metalcasters at Government Affairs Fly-in in D.C. MILWAUKEE, WIS – Rob Cowen, president and CEO of Badger Alloys, will represent Wisconsin foundries…

How 3D Printing can Improve your Casting Process

3D printing in casting manufacturing The innovation of 3D printing has revolutionized the sand casting process. Forward-thinking foundries are using this technology to produce polymer patterns and sand molds and cores. Ideal for low-volume casting needs, both types of tooling…

Badger Alloys Exhibits at American Foundry Society’s MetalCasting Congress

MILWAUKEE, WIS — Badger Alloys, Inc., a full-service castings manufacturer in Milwaukee, Wisconsin, and a long-time member and supporter of American Foundry Society (AFS), exhibited at the association’s MetalCasting Congress April 23 – 24, 2024, at the Baird Center in…

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