A color coded model image of magma with a temperature scale on the right side.

Engineering Services

  • 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
  • Certified foundry engineering team

    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 certified 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.

    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. 

    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.

    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.

    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

    Engineering Team Qualifications

    MAGMA-trained engineers on site. This extraordinary level of training allows our professionals to enhance tooling designs and anticipate potential defects in advance, resulting in shorter lead times and reduced overall costs to our customers.

    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.

    Advanced Equipment and Software

    We continually research and invest in the latest manufacturing technologies as they become available. Some of our latest investments include:

    Contact Badger Alloys today to get project assistance on your prototype casting project!

    Sand Casting

    Sand Casting Services

    Whether you need a few specialty components or a large volume of castings, Badger Alloys is equipped to meet your demands.

    Pattern Making

    The best components start with a qualified and experienced casting pattern maker. Our highly skilled patternmakers create custom patterns based on your exact specifications.

    Machining

    When your casting applications demand machining to tight tolerances, you need a partner you can rely on to provide consistently high quality, part after part.

    Engineering

    Magma

    Our team of engineers works collaboratively with our patternmakers and foundry personnel to help customers achieve their desired result.

    Robot and 3D Technologies

    Badger Alloys offers the latest in additive and subtractive manufacturing.