Up close image of a hardwood Sand Casting Pattern Maker.

Pattern Shop

Sand Casting Foundry with Advanced Pattern Making Capabilities

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 pattern makers
  • 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.

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 lb.

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. 

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.


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.



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.