Ironforge runs investment casting and chemically-bonded sand lines under one roof. One prototype or fifty thousand a year — steel, stainless, aluminum, high-nickel — held to the tolerance on the print and certified on the dock.
Castings shipped to programs in aerospace, energy, defense, and heavy industry
Most shops run one line and force every job through it. We run both and route your part to whichever delivers the geometry, finish, and price your program actually needs.
Lost-wax precision for thin walls, fine detail, and as-cast surfaces down to 125 Ra. Pours from a few ounces to 80 lb in steel, stainless, and superalloy.
Airset and no-bake molds for heavy sections and short-run economics. Parts from 2 lb to 1,800 lb — and you start without cutting a steel die.
Printed patterns and 3D-printed sand molds put a first-article part in your hand in weeks. A hard die would take four months and a five-figure check.
Melt, mold, finish, machine, and inspect under one roof and one cert package. Your part never gets drop-shipped across three states to get finished.
What comes off the floor
Carbon and low-alloy steels, 300- and 400-series stainless, aluminum, bronze, and high-nickel grades. Every heat is verified on the spectrometer before it touches a mold.
Optical emission analysis on every heat, every shift. Chemistry gets confirmed before the metal pours — never argued about after a part fails on your bench.
WCB, WCC, 8620, 4140 and more. Tough, weldable, heat-treatable, and built to take a load.
CF8M, CF3M, 17-4 PH and duplex grades for corrosion service and pressure-rated work.
A356, 535, and silicon-aluminum bronzes for light, conductive, or saltwater duty.
In-house anneal, normalize, quench-and-temper, and solution-and-age. Mechanicals certified to your spec — not estimated from the grade next door.
A demonstration sampler across the lines we run. Real geometry, real alloys, real programs — names withheld where the contract says so.
Closed-vane impeller, 11" diameter, poured in CF8M and CT-scanned for internal soundness before machining. Eight-week program from print to first article.
Pressure-rated body with cored passages, cast to 125 Ra so the bores finish with a single light cut. Solution-and-aged to H1075 in-house.
640 lb airset housing for a drivetrain build. Printed pattern skipped the four-month tooling wait and held the bearing bores to drawing.
High-nickel diffuser for a hot-section program. Radiographed to ASTM E192 Level 2, shipped with full traceability to the heat.
1,200 lb bronze manifold for shipboard cooling. Dye-penetrant inspected on every flange face, finished and hydro-tested before it left the dock.
A run of structural brackets on an ITAR-controlled program. Full AS9102 first-article package, then steady monthly releases off the same tooling.
Quality here is a department with a budget and a sign-off, not a stamp somebody adds at the end. Every casting ships with paper that ties it back to the metal it came from.
Every casting carries a heat number that links it to its chemistry, pour log, and mechanical results — for the life of the part.
Digital X-ray and CT scanning verify internal soundness against ASTM standards before a part ever sees the truck.
First-article and in-process inspection on coordinate measuring machines, reported as a full PPAP or to your AQL.
Magnetic-particle, dye-penetrant, and ultrasonic testing run by certified technicians. No outside lab queue holds your ship date.
Mill-grade chemical and physical test reports issued with every shipment, signed and EN 10204 3.1 compliant.
Full production-part-approval and first-article packages built to AS9102 for regulated and defense programs.
“We sent Ironforge a print our last foundry called impossible. First article came back in three weeks, in tolerance, with the X-ray film in the box. They have had the program ever since.”
“Running both processes means they don't talk us into the expensive one. They quoted sand for the heavy housings and investment for the precision body. Our landed cost dropped fourteen percent.”
“Traceability is the whole game for us. When an auditor pulls a casting off the line, the heat number walks them straight back to the chemistry. Ironforge never makes us go looking for it.”
Investment castings from a few ounces to about 80 lb, and sand castings from 2 lb to 1,800 lb. We take single prototypes through annual volumes past fifty thousand pieces, and we route each job to the line that fits the run.
Most RFQs are quoted within 48 hours. With printed patterns and 3D sand molds, first-article castings are typically in your hand within three weeks — instead of the four months hard tooling would cost you.
Both. We ship as-cast, partially machined, or finished-to-print complete with heat treat, NDT, surface finishing, and assembly. One supplier, one cert package, one part number on the PO.
ISO 9001 and AS9100 certified, with material certs to EN 10204 3.1 and inspection packages to AS9102 PPAP and FAI. We support ITAR-controlled and defense programs.
Yes. Send the print and the spec. Our engineers will model the part, advise on gating and draft, and flag anything that fights the process before you commit a dollar to tooling.
Upload a drawing or a STEP file and our engineers return a quote with the process, alloy, tolerance, and lead time spelled out. A real number from a real metallurgist, not a form letter.