Waukesha Foundry

What Waukesha Foundry does

Waukesha Foundry, Inc. is a privately held U.S. metal casting manufacturer founded in 1912 and headquartered in Waukesha, Wisconsin, operating with 101-250 employees. The foundry produces custom cast components spanning 1 to over 6,000 pounds in more than 200 alloys, using chemically bonded (no-bake) sand molding, consumable pattern ceramic molding (FoamCast/PMMA/SLA investment casting), and what the company identifies as North America's largest vacuum induction melting furnace (4,000-pound capacity, 1,000 kW, 3,200°F). It owns proprietary anti-galling alloys under the Waukesha Metal brand (WM88, WM126, WM23BI, WM54C, WM3) and produces stainless steels, nickel superalloys (including Hastelloy, Inconel, Waspaloy), and Invar 36 for aerospace composite tooling. Value-added services include in-house CNC machining, ASNT Level II/III NDT (radiographic, magnetic particle, liquid penetrant, hydrostatic), finishing, and assembly.

The company sells into six vertical markets: defense (70+ years of experience and P900 armor plate production), aerospace (vacuum-tight face sheet tooling), food processing (FDA-approved WM88 sanitary equipment), petrochemical (WF-Repco fittings acquired from APV in 1995), industrial equipment, and pumps & valves (including data center cooling). Its go-to-market is dual-track: enterprise direct sales via phone, email, and website quote forms for custom work, complemented by an e-commerce storefront selling WM88 and WM126 bar stock to SMB and individual buyers with quantity-tiered pricing. Distribution is global; the company also runs a low-cost country sourcing program through India partner foundries with Waukesha-employed quality staff on-site.

Revenue is generated primarily through custom casting project contracts on a quote basis, often structured as multi-year programs; bar stock is sold on transactional unit pricing; sourcing services function as a professional services revenue stream. Waukesha holds ISO 9001:2015, AS9100D, ITAR/DDTC, ASME IX, and RoHS/REACH certifications, positioning it as a qualified supplier to prime contractors in regulated defense and aerospace supply chains. In 2026, the company is pursuing DoD automation grants and has hired its first dedicated Business Development and Sales Director, partnering with ARM Institute, Titan Robotics, and Ohio State University on foundry automation initiatives.

Name

Waukesha Foundry

Legal name

Waukesha Foundry Inc.

Website

https://waukeshafoundry.com

Company type

Private

Founded year

1912

Operating status

Operating

Headcount range

101–250 employees

Short description

Waukesha Foundry is a privately held U.S. metal casting manufacturer (est. 1912) producing custom cast components in 200+ alloys for defense, aerospace, food processing, petrochemical, industrial, and pump & valve customers, operating North America's largest vacuum furnace and proprietary WM-series anti-galling alloys.

Ownership category

akta.pro rank

Product category

Custom Metal Castings

NAICS

Foundries (3315), Iron Foundries (331511), Other Nonferrous Metal Foundries (except Die-Casting) (331529)

SIC

Iron & Steel Foundries (3320), Nonferrous Foundries (Castings) (3360)

akta.pro primary industry

Steel Casting (Continuous Casting, Ingots, Semi-Finished Slabs/Billets/Blooms) (IMAKABAD)

akta.pro secondary industries

Aluminum Casting & Ingot/Billet/Slab Production (IMAKACAE), Industrial Furnaces, Kilns & Thermal Processing Equipment (IMAHAEAE)

Keywords

• Metal casting manufacturing
• Custom industrial castings
• Anti-galling alloys
• Investment casting services
• Vacuum furnace melting

Headquarters

HQ city

Waukesha

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Supply Chain, Personnel, Infrastructure, Operations, Technology or R&D, Marketing or Sales

Revenue model

1. Custom Castings Manufacturing: Production of custom metal castings in over 200 alloys, ranging from 1 to over 6,000 pounds. Serves aerospace, defense, food processing, industrial, pumps & valves, and petrochemical industries with value-added services including machining, assembly, painting, coating, and finishing.
2. Bar Stock Products: Direct sales of proprietary alloy bar stock including WM88, WM126 products through e-commerce storefront with tiered pricing based on quantity.
3. Low-Cost Country Sourcing Services: Global sourcing services for cast components from India partners, offering sand casting, investment casting, polishing, machining, with quality oversight from Waukesha-employed staff at partner locations.

Pricing tiers

Go-to-market motion2 records

Distribution channels2 records

Marketing channels6 records

Core offering

Waukesha Foundry is a metal casting manufacturer producing custom cast components in over 200 alloys (1 to 6,000+ pounds) using no-bake sand molding, investment casting (Foamcast/PMMA/SLA), vacuum furnace melting, CNC machining, and non-destructive testing. The company also sells proprietary anti-galling alloy bar stock (WM88, WM126, etc.) through its own e-commerce storefront. It operates as a single-source supplier for aerospace, defense, food processing, petrochemical, industrial, and pump & valve customers.

Product overview

Waukesha Foundry is a single-source supplier of precision metal castings and manufacturing services, operating as a century-old foundry (est. 1912) that produces intricately shaped cast components. The company offers multiple manufacturing processes including chemically bonded sand molding, consumable pattern ceramic molding (investment casting), vacuum furnace melting, and CNC machining. Their core portfolio includes over 200 alloys with proprietary anti-galling alloys (WM88, WM23BI, WM54C, WM126, WM3), stainless steels, nickel superalloys, and Invar 36. Value-added services include non-destructive testing, assembly, and low-cost country sourcing. The company serves aerospace, defense, food processing, petrochemical, industrial equipment, and pump & valve markets through products like WF-Repco petrochemical fittings, bar stock (WM88/WM126), and precision aerospace tooling castings.

Differentiator

Problem solved

Functional benefit

Brands

• Waukesha Metals: Product line featuring specialty anti-galling and corrosion-resistant alloys including WM88, WM126, WM23Bi, and WM54C, offered as bar stock.
• WF-Repco

Products and services

• Casting Manufacturing Services Full-service metal casting manufacturing using chemically bonded sand (no-bake), patternless robot molding, consumable pattern ceramic molding (FoamCast/PMMA/SLA), 3D printed sand molds, and traditional tooling. Produces castings from 1 to over 6,000 pounds in over 200 different alloys for aerospace, defense, food processing, industrial, pumps & valves, and petrochemical customers.
• Vacuum Furnace Services Advanced vacuum induction melting services using North America's largest vacuum furnace (4,000-pound capacity, 1,000 kilowatts, up to 3200°F) with argon refining and magnetic stirring. Enables precision control over alloy chemistry and high-purity castings for aerospace and defense applications.
• CNC Machining Services Precision CNC machining, cutting, turning, and grinding services using multi-axis machines (Mori Seiki, Feeler, Haas, Johnson lathes; Okuma, Doosan, Bullard vertical turning centers; Haas, Cincinnati mills). Includes finishing options such as anodizing, powder coating, electropolishing, and plating.
• Non-Destructive Testing (NDT) Services Comprehensive in-house NDT with SNT-TC-1A/NAS-410-4 Level II/III certified inspectors. Capabilities include radiographic inspection up to 6 inches material penetration, digital radiography, magnetic particle inspection (wet fluorescent), liquid penetrant inspection, and hydrostatic testing, plus chemical, mechanical, and metallographic inspections.
• No-Bake Sand Molding Phenolic Urethane No Bake (PUNB) sand molding process using silica and specialty sands with water-based resins. Features variable cure times, good work time to strip time ratio, flowability, storage life, and reclaimable sand.
• Consumable Pattern Ceramic Molding (Investment Casting) Full Mold Investment Casting process using foam (PMMA) or stereolithography (SLA) patterns instead of traditional wax. Ideal for complex castings with tight tolerances and excellent surface finish. Size range: 1 lb to 1,000 lbs, section sizes from 0.250" to 14", surface finish up to 300 RMS.
• Low-Cost Country Sourcing Global sourcing services for cast components through partnerships with foundries in India, including sand casting, investment casting, polishing, and machining. Waukesha Foundry employs full-time staff at partner locations for quality oversight, with 20+ years of international procurement experience.
• Waukesha Metal 88 (WM88) Bar Stock Proprietary nickel-based anti-galling alloy (UNS N26055, ASTM A494 CY5SnBiM) invented in 1954. FDA and 3-A sanitary standards approved for food contact. Offers superior galling and corrosion resistance in metal-to-metal contact without lubrication. Available in round bar stock from 0.75" to 3.00" diameter via the company's e-commerce storefront.
• Waukesha Metal 126 (WM126) Proprietary copper-based anti-galling alloy (Tin 3.50%, Chromium 20.00%, Aluminum 1.00%, Zinc 20.00%, Manganese 20.00%). Tensile strength 50 ksi, Yield 39 ksi, Elongation 4.0%, Hardness 150 BHN. Ideal for gears, bushings, and bearings in food processing and industrial applications.
• Waukesha Metal 23BI (WM23BI) Proprietary anti-galling alloy with higher yield strength and hardness than WM88. Carbon, manganese, bismuth, tin, nickel, and zinc blend. Hardness 200 BHN typical, Yield 48 ksi TS, 45 ksi YS, 3.5% elongation. Designed for low-temperature applications including ice cream processing.
• Waukesha Metal 54C (WM54C) Nickel-based anti-galling alloy with exceptional high-temperature resistance. Composition: Sn 8.00%, Ni Balance, Zn 8.00%, Mn 2.00%, Ag 6.00%. Tensile strength 75 ksi, Yield 56 ksi, Elongation 7%, Hardness 220 BHN typical. Suitable for food processing, chemical processing, and high-temperature applications.
• Waukesha Metal 3 (WM3) Copper-based alloy commonly referred to as 'dairy metal'. Resists stress corrosion cracking, crevice corrosion, and galling. High thermal conductivity. Ideal for food processing equipment, seawater applications, pharmaceutical processing pumps, gears, bushings, and bearings.
• Invar 36 Nickel-iron alloy (36% nickel, 64% iron) with very low coefficient of thermal expansion. Maintains dimensional stability up to 500°F. Waukesha Foundry is the top producer of vacuum-tight cast Invar 36 for composite tooling in aerospace applications.
• Stainless Steel Castings Over 30 grades of cast stainless steel including austenitic (CF8/304, CF8M/316), ferritic (CB-30), martensitic (CA15/410, 420, 440), duplex (CD4MCuN), precipitation-hardenable (CB7Cu-1/17-4, CB7Cu-2/15-5), and super austenitic (CN7M/Alloy20, CN3MN/AL6XN) stainless steels.
• Nickel Superalloy Castings Complete range of nickel-based alloys including IN-100, Hastelloy X, Hastelloy B-2 (N7M), IN-713C, Hastelloy C (CW12MW), IN-718, Inconel 600 (CY40), Hastelloy C4C (CW2M), Inconel 625 (CW6MC), Hastelloy G, and Waspaloy. Temperatures up to 2000°F for gas turbine and aerospace applications.
• WF-Repco Petrochemical Fittings Petrochemical fittings and assemblies brand acquired from APV Refinery Products Co. in 1995. Product line includes Type 10 Mule Ear, Type 20 Horseshoe, Type 30 Screw Top Plug Headers, Type 11 Heavy Backwall U-Bends, elbows, wyes, tube sheets, and tube hanger components for oil refinery applications.
• Aerospace Tooling Castings Vacuum-tight cast face sheet tooling and precision aerospace components including nose cones, IN100 forming dyes, and complex geometries for airframe and structural components. Features 3D scanning capabilities and near-net-shape casting expertise.
• Defense Industry Castings Over 70 years of experience producing complex defense system castings, including armor plates and highly engineered components. Capabilities span low- to production-volume runs, multiple casting processes, wide range of alloys, lighter weight materials, high strength alloys, and challenging mechanical requirements including P900 armor program work.
• Precision Pump & Valve Castings High-performance castings for critical pump and valve systems including housings, bodies, covers, impellers, and complex fluid control components. Serves data centers, commercial construction, chemical plants, food processing, marine systems, medical equipment, and water/wastewater applications.
• Food Processing Equipment Castings Anti-galling cast components for food processing including positive displacement pumps, filler plugs, and sanitary equipment. Features FDA-approved alloys like WM88 with corrosion resistance against food ingredients and cleaning compounds.

Quantifiable outcome

• Galling resistance 5x better than 316 stainless steel
• +3 more outcomes

Named customers5 records

Segments6 records

Ideal customer profiles6 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature6 records

Partnerships

Six partnerships are on record, tiered minor and core.

• APV Refinery Products Co. (acquired)minorOthers · 1 January 1995Acquired from APV of UK in 1995, including patterns and engineering drawings for fittings originally produced by Key Co., Sivyer Steel, Ohio Steel, and Lebanon Steel. Expanded to include WF-Repco product line.
• Titan RoboticscoreStrategic or Co-development PartnerCollaboration with Titan Robotics as part of automation initiative hosting at Waukesha Foundry, focused on future of robotics and advanced automation in foundry industry.
• The Ohio State UniversitycoreStrategic or Co-development PartnerAcademic partnership through ARM Institute involvement, collaborating on automation and robotics research for manufacturing applications in foundry industry.
• ARM (Advanced Robotics for Manufacturing) InstitutecoreStrategic or Co-development PartnerActive participation in ARM Institute initiatives including automation projects, robotic casting and forging forums, and workforce development for advanced manufacturing.
• Office of the Secretary of Defense (OSD)coreStrategic or Co-development PartnerCollaboration through Department of Defense-supported automation initiative, visiting Waukesha Foundry to discuss automation needs for defense industrial base.
• India Foundry PartnersminorChannel Partner/ Reseller/ DistributorLow-cost country sourcing partners in India for sand casting, investment casting, polishing, and machining services. Waukesha employs full-time staff at partner locations for quality oversight.

Scale indicators6 records

Recent moves6 records

Expansion highlights6 records

Direct peers

• Metaltek International: Specialty nonferrous and heat/corrosion-resistant alloy foundry offering investment, sand, and centrifugal casting across a similar 200+ alloy range. Closest direct peer in terms of custom alloy breadth, mid-market size, and niche specialty positioning.
• Waupaca Foundry: One of the largest iron foundries in the US, also headquartered in Wisconsin. Directly comparable: produces iron castings for similar industrial, automotive, and heavy-equipment end markets with vertically integrated machining and finishing. Same regional labor market, same customer verticals.
• Grede Holdings: Mid-market iron and steel casting manufacturer serving automotive, heavy truck, and industrial machinery. Direct competitor in ferrous casting with overlapping geographies and similar end-market exposure to North American industrial customers.
• Precision Castparts Corp (PCC): Berkshire Hathaway-owned producer of investment castings, nickel superalloys, and vacuum-melted components for aerospace and defense. Closest large-scale analog to Waukesha's vacuum furnace + investment casting + aerospace superalloy offerings.
• Howmet Aerospace: Global leader in nickel and cobalt-based superalloy and titanium castings for jet engines and aerospace structural components. Direct overlap with Waukesha's superalloy / vacuum melting capability serving aerospace and defense OEMs.
• Dotson Iron Castings: Family-owned US iron foundry producing high-specification castings for construction, agriculture, and industrial OEMs. Comparable in scale, ownership profile, and vertical mix to Waukesha's ferrous casting line.
• Hitchiner Manufacturing: Investment castings specialist focused on aerospace, defense, and industrial gas turbine components. Directly competes with Waukesha's consumable pattern ceramic molding (Foamcast/PMMA/SLA) investment casting line for similar complex-geometry applications.
• Eagle Alloy: Nonferrous (aluminum and copper-based) investment casting foundry serving pumps, valves, food processing, and industrial OEMs. Direct competitor to Waukesha's nonferrous specialty alloy and pump/valve market exposure.

Broad incumbents

• Marmen Welding & Machining: Large North American machining and fabrication specialist serving wind energy, power generation, aerospace, and industrial machinery. Comparable customer verticals and integrated machined-component offering, but bigger, broader, and not niche specialty alloys.

Others

• Vulcan Group / Vulcan Engineering: Supplier of foundry equipment, furnaces, casting automation, and turnkey foundry systems. Sells into Waukesha's addressable market and is an adjacent enabling participant in advanced manufacturing automation that Waukesha is implementing.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat6 records

Key risks6 records

Key highlights7 records

Customer concentration

• LinkedInlinkedin.com/company/waukesha-foundry-inc

Compliance9 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles5 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Waukesha Foundry