Tupy, Waupaca Foundry, MAT Foundry Group, Grede, Impro Precision, MetalTek, Grainger & Worrall, Harrison Castings, Badger Alloys and Benton Foundry are the ten sand casting companies covered here, with our own shop described the same way at the end. Each entry gives only what the company itself publishes: metals poured, casting weight window, molding process, plants and certifications.
Read the metals first, because that filter does most of the work. Three of the ten pour no cast iron at all — Grainger & Worrall and Harrison Castings are aluminum houses, and Badger Alloys pours steel, stainless, nickel-base, bronze and brass — while six of the rest pour iron and nothing else. What your part is made of eliminates most of this list before weight, volume or geography comes up.
This is not the offshore list — Top 10 Sand Casting Factories in China covers Chinese plants quoting export work, and only our own entry appears on both.
Tupy
Tupy is a Brazilian structural cast iron producer — gray iron, ductile iron and compacted graphite iron, with no steel and no aluminum anywhere in its offering. Its foundries are in Joinville and Betim in Brazil, Saltillo and Ramos Arizpe in Mexico, and Aveiro in Portugal, backed by offices in the US, Germany, Italy and the Netherlands.
The parts are automotive and off-highway through and through: engine blocks, cylinder heads, crankshafts, bearing caps, brake shoes, turbine housings, rear axle bridges and exhaust manifolds. Machining runs in house in Brazil and Mexico. The company holds IATF 16949 alongside ISO 9001, 14001, 45001 and 50001.
What Tupy does not publish is a casting weight range or a molding process. Its pages catalogue parts rather than capabilities, so there is nothing to size a one-off housing against — the fit question here is whether your part looks like an engine block, not how heavy it is.
Waupaca Foundry
Waupaca Foundry is the high-volume iron end of this list: gray, ductile, high-strength ductile and austempered ductile iron, cast from 2 to 350 lb on vertical molding machines the company designs and builds itself.
Its plants sit in Waupaca and Marinette, Wisconsin and Tell City, Indiana. Waupaca states it melts nearly two million metric tons of iron a year, which puts the narrow weight window in context — this is series production for automotive, off-highway, commercial vehicle, industrial, rail and oil and gas.
All foundry locations hold ISO 9001:2015 and IATF 16949:2016. No ASTM class or grade designations and no tolerance figures appear anywhere on the site, so grades and dimensional expectations get set in the quote conversation rather than read off a page.
MAT Foundry Group
MAT Foundry Group is an automotive braking and driveline iron group — gray and ductile iron only — headquartered in Poole, Dorset, with foundries and machining plants across the UK, Germany, the Czech Republic, Denmark, Poland, Mexico and China.
The product list is narrow and deep: brake discs, drums, calipers and carriers, differential cases, backing plates, camshafts and balancing shafts, plus industrial hydraulic housings and wheel flanges. The group states it produces over 350,000 tons of iron a year for OEM and aftermarket customers.
No casting weight range, no molding process and no certification is named on any of the group’s pages, and the homepage, products page and contact page give three different counts of how many facilities the group runs. The product list is the usable signal: if your part is not a brake or driveline component in series volume, this is not a natural quote.
Grede
Grede casts ductile, gray and specialty iron for safety-critical chassis, suspension and drivetrain parts, from six foundries — Biscoe NC, Wauwatosa and Reedsburg WI, Meadville PA, New Castle IN and St. Cloud MN — plus machining at Biscoe, Meadville and Menomonee Falls, WI.
Its markets are industrial, commercial truck and automotive: heavy-duty truck engine and chassis components, large axle housings for heavy equipment and agriculture, and hydraulic component castings. Design support includes casting process simulation and 3D-printed sand cores.
Grede is the least specific publisher on this list. Across its site there is no casting weight range, no iron grade designation, no certification and no molding process named — the design page discusses helping determine the grade of iron without naming one. Shortlisting Grede means a conversation, not a spec comparison.
Impro Precision
Impro Precision’s sand casting arm pours ductile iron, gray iron and compacted graphite iron on green sand and resin sand lines, using both fully automatic and floor molding. No steel is offered in sand, even though the company’s investment casting and machining businesses handle stainless and aerospace alloys.
Impro manufactures in Wuxi, Jiangsu, with further entities in San Luis Potosí in Mexico, Diamond Bar and Naperville in the US, Luxembourg and Germany. Sand cast parts include engine blocks, cylinder heads, frames, brackets, high-horsepower engine manifolds, impellers, housings and gearbox parts.
Certifications are held entity by entity rather than group-wide — ISO 45001 at the Wuxi entities, IATF 16949 for investment casting and machining at the Mexico plant, AS9100 at Plant 3, Nadcap heat treating and welding at named subsidiaries — so confirm coverage for the plant that would actually pour your part. No sand casting weight range is published anywhere.
MetalTek International
MetalTek’s sand casting is one division — Carondelet, in Pevely, Missouri — and it is the heavy end of this list: ferrous sand castings to 36,000 lb pour weight and 18,000 lb ship weight, in over 300 ferrous alloy grades including stainless and HY-80.
The rest of MetalTek is centrifugal and investment casting. Molding at Carondelet covers an in-house pattern shop with IMF, patternless, automated isocure, no-bake and pit molding, and inspection covers magnetic particle, liquid penetrant and radiographic testing along with mechanical and chemical analysis.
MetalTek also publishes what almost nobody else here does: an acceptable as-cast surface finish of 250 to 500 RMS with moderate tolerances, and the expectation that post-cast machining is how you get better than that. Carondelet holds ISO 9001:2015, NORSOK M650 Rev 4, PED material manufacture, HY-80 to NAVSEA Tech Pub 300 and ASNT-TC-1A Level II inspectors, aimed at defense, mining, petrochemical, energy and steel mill work. There is no gray or ductile iron in this division.
Grainger & Worrall
Grainger & Worrall is aluminum only — complex aluminum sand casting and machining from Bridgnorth, Shropshire, with a second foundry in Worcester acquired in 2016 — so no ferrous part belongs on its quote list.
It runs four casting routes: gravity, low pressure with an in-house rollover process, an automated precision sand cast line, and Gigacasting for large single-piece aluminum structures. The automated route is described as annual volumes of 1,000 to 10,000 units with capacity for up to 90,000 castings, which places the company between prototype and low series rather than in commodity volume.
It is one of the few here to name alloys at all: aluminum-silicon and aluminum-copper grades from A356.2 up to motorsport and aerospace alloys such as 201, verified by OES to ASTM E1251. No casting weight range, no tonnage and no ISO certification appear on the site.
Harrison Castings
Harrison Castings is the other aluminum-only house here: aluminum sand castings up to 350 kg, over 1,500 tonnes a year, from a single site on Gough Road in Leicester.
In-house work covers pattern making, cold-box core making, heat treatment including precipitation treatment to TE condition, rotary degassing, density indexing and spectrograph analysis, all under BS ISO 9001:2015.
One detail matters if you want a finished part on one purchase order: CNC machining comes through partners, not in house. The company names no aluminum alloy designations anywhere.
Badger Alloys
Badger Alloys pours castings from 10 to over 4,000 lb in more than 200 alloys — high alloy and stainless steel, carbon and low alloy steel, nickel-base, bronze, brass and wear-resistant grades — and no cast iron at all.
Everything happens on one Milwaukee campus: pattern making in wood, polyurethane and metal, engineering, machining, and a rapid-response route using robotic patternless molding and 3D printing. It holds ISO 9001:2015 and PED certification and serves industrial valves, pump systems, defense, water treatment, energy and oil and gas, chemical, pharmaceutical and food equipment.
The alloy claim needs testing against your own callout. Badger names alloy families but no ASTM or UNS grade designations, so 200-plus alloys is a capability statement rather than a catalogue you can match a specification to. No molding process, tonnage or tolerance figure is published either.
Benton Foundry
Benton Foundry publishes more hard specification than anyone else on this list: gray, ductile and austempered ductile iron from 1 to 250 lb, on named DISA and Hunter automatic lines with flasks from 14 × 19 in up to 28 × 32 in, from one plant in Benton, Pennsylvania.
Core making is cold-box and shell, and quality work runs on a CMM, a Romer 3D scanner and a spectrographic and metallographic lab, with cradle-to-grave traceability, PED certification, Ductile Iron Society Certified Producer status, and ISO 9000 certification as the company itself states it — not a dated ISO 9001 edition.
The number that matters for a mid-volume buyer is order size: more than 5,500 part numbers for roughly 300 customers, with releases as small as 50 molds.
Kurt Foundry
Kurt Foundry is the ferrous resin sand shop on this list: carbon steel, stainless, ductile iron and gray iron poured from 1 to 1,000 kg (2 to 2,200 lb) in furan resin sand, at one plant in Weifang, Shandong.
The grades are published rather than described. Carbon steel is ASTM A27 / WCB at 415 to 485 MPa tensile and 205 to 250 MPa yield; stainless is CF8, CF8M and CF3M at 485 to 550 MPa tensile; ductile iron is ASTM A536 in 60-40-18, 65-45-12 and 80-55-06; gray iron is ASTM A48 classes 20 through 40. As-cast tolerance is CT10 to CT12 per ISO 8062, with surface finish Ra 12.5 to 25 µm.
Molds are laid out in Magmasoft before tooling is cut, and patterns and core boxes are made in house on CNC. Melting is medium-frequency induction with pre-pour spectrometry and material test reports. Downstream work covers 5-axis milling and turning, heat treatment, shot blasting, plating and passivation, UT, MPI and X-ray, CMM dimensional reports, and DDP delivery with ISPM-15 packaging.
Which Sand Casting Company Is Best for Your Project
The right one is the company that pours your metal in your weight class, and that pair of filters removes most of these eleven before price, lead time or location enters the conversation.
| Company | Metals poured | Published casting weight | Main sites |
|---|---|---|---|
| Tupy | Gray, ductile, CGI | Not published | Brazil, Mexico, Portugal |
| Waupaca Foundry | Gray, ductile, high-strength ductile, ADI | 2–350 lb | Wisconsin, Indiana |
| MAT Foundry Group | Gray, ductile | Not published | UK, Germany, Czech Republic, Denmark, Poland, Mexico, China |
| Grede | Ductile, gray, specialty iron | Not published | NC, WI, PA, IN, MN |
| Impro Precision | Ductile, gray, CGI | Not published | Wuxi China, Mexico, US |
| MetalTek (Carondelet) | 300+ ferrous alloys incl. stainless | To 18,000 lb ship weight | Pevely, Missouri |
| Grainger & Worrall | Aluminum | Not published | Bridgnorth and Worcester, UK |
| Harrison Castings | Aluminum | Up to 350 kg | Leicester, UK |
| Badger Alloys | Stainless, steel, nickel, bronze, brass — no iron | 10–4,000+ lb | Milwaukee, Wisconsin |
| Benton Foundry | Gray, ductile, ADI | 1–250 lb | Benton, Pennsylvania |
| Kurt Foundry | Carbon steel, stainless, ductile, gray | 1–1,000 kg (2–2,200 lb) | Weifang, China |
Alloy family cuts first. For aluminum there are only Grainger & Worrall and Harrison Castings; for cast iron, Tupy, Waupaca, MAT, Grede, Impro, Benton and ourselves; for cast steel or stainless in sand, only Carondelet, Badger Alloys and ourselves, since the iron houses pour none of it.
Weight cuts second, where it can. A production iron part under 250 lb points at Benton and Waupaca; anything above 5,000 lb leaves Carondelet alone on the list. Five companies publish no weight range at all, so with Tupy, MAT, Grede, Impro and Grainger & Worrall the ceiling can only be found by sending the drawing.
Volume splits the survivors. Waupaca, MAT and Tupy are program-volume automotive suppliers whose economics assume thousands of parts a year; Benton takes releases of 50 molds; Badger and Grainger & Worrall run patternless and prototype routes built for one-off and low-series work.
Certification settles some shortlists outright. NORSOK M650 and NAVSEA HY-80 approval exist only at Carondelet here; IATF 16949 sits with Waupaca and Tupy; PED covers Badger, Benton and Carondelet. Three companies on the list name no certification at all on their own pages.