A Robotic patternless molding machine drilling into a mold with its robotic arm.

Robotic Patternless Molding and 3D Technologies

  • Robotic patternless molding WATCH OUR VIDEO!
  • Prototype casting
  • 3D-printed sand molds and cores
  • 3D-printed plastic patterns

Next Generation Manufacturing

With a commitment to quality through constant re-investment and upgrading of equipment and technologies, Badger Alloys offers the latest in additive and subtractive manufacturing. By taking advantage of our robot and 3D technologies – including 3D modeling, solidification analysis, 3D printed cores and robotically milled tooling – our customers are able to work with our engineering team to manipulate castings in the digital space and make sure they are getting the best quality casting.

Prototype Casting and Robotic Patternless Molding

OEMs and other manufacturers require castings with tight tolerances and quick turnaround. Prototypes and robotic patternless molding can oftentimes provide the desired casting in the shortest amount of time.

Short-run, complex castings and/or those that require a prototype are ideal candidates for Badger Alloys to mill using our KUKA Quantec six-axis robot. With our robot, we are able to create molds for small to large castings, up to 4,000 pounds and a mold size of 8’X8’. Investment in this equipment has allowed us to provide casting customers a lower cost, more efficient, highly precise alternative to traditional tooling methods.

In general the benefits of prototype casting and patternless molding include:

  • Shorter design cycle
  • Decreased up-front capital investment by 20 to 30 percent
  • More design freedom
  • 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 percent
  • Elimination of equipment storage and/or maintenance cost

3D Printed Sand Molds and Cores

For low-volume castings, 3D printed sand molds and cores can be your most efficient and affordable option. Using 3D printed sand molds can help you shorten your production lead time and bring your product to market quickly. 3D printed sand molds can be recreated easily from file, eliminating the need to store or physically move your patterns.

3D Plastic Patterns

3D plastic printing is an alternative method for producing traditional pattern equipment in a potentially lower cost material and in a shorter timeframe. This method can be ideal for low-volume, highly complex casted parts and prototypes. If you have a higher-volume need, traditional tooling can be more economical. Our engineers can consult with you on the best method for your project.

To determine what process is best for your casting needs, download our whitepaper on tooling methods or contact us today.


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.