Badger Alloys

What Badger Alloys does

Badger Alloys is a family-owned, full-service sand casting foundry headquartered in Milwaukee, Wisconsin, founded in 1966 as Badger Brass & Aluminum. The company produces custom ferrous and nonferrous castings ranging from 10 to over 4,000 pounds in 200+ alloy formulations using an airset (no-bake) molding process with chemical binders. Its single Milwaukee campus integrates pattern making, foundry operations, in-house machining, engineering, rapid response technologies (3D-printed sand molds, KUKA Quantec robotic patternless molding, FARO/Creaform 3D scanning, MAGMASOFT solidification analysis), and a full quality assurance and NDT laboratory, allowing customers to receive castings from pattern through finished machined product under one supplier.

The company serves OEM and industrial customers across industrial valves and pumps, defense and marine (NAVSEA, MIL-STD, ITAR), water treatment, energy and oil & gas, pharmaceutical equipment, and food and beverage bulk handling. Notable named enterprise customers include Flowserve and Milwaukee Valve (Supply Chain Partner of the Year 2023). Certifiability is a moat — ISO 9001:2015 (re-certified through 2026), PED, ASME Sec IX, ASTM-A488, NACE MR0103/MR0175, NAVSEA TECH PUB 278, and Dodd-Frank conflict minerals compliance — positioning the company to win defense, naval, and EU pressure-equipment work that competitors without comparable audit history cannot access.

Revenue is generated project-by-project via direct enterprise sales through a technical sales engineering team, with custom quote-based pricing by casting weight tier (5-10 lb through 1,001-5,000 lb), material type, quantity, and value-added services (machining, engineering, prototyping). Distribution is exclusively direct — no channel partners or resellers. Pricing is not publicly disclosed, and the company is privately held with no institutional outside investment, transitioning ownership to third-generation family members under President & CEO Rob Cowen (since 1997).

Name

Badger Alloys

Legal name

Badger Alloys, Inc.

Website

https://badgeralloys.com

Company type

Private

Founded year

1966

Operating status

Operating

Headcount range

101–250 employees

Short description

Badger Alloys is a family-owned Milwaukee sand casting foundry producing custom ferrous and nonferrous castings from 10 to 4,000+ pounds in 200+ alloys for industrial OEMs in valves, pumps, defense, water treatment, and energy.

Ownership category

akta.pro rank

Product category

Sand Casting Foundry / Custom Metal Castings

NAICS

Steel Foundries (except Investment) (331513), Aluminum Foundries (except Die-Casting) (331524), 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), Specialty & Alloy Steel (Stainless, Tool Steel, Electrical Steel, High-Strength/HSLA) (IMAKABAJ)

Keywords

• Sand casting services
• Custom metal castings
• Ferrous nonferrous alloys
• Foundry manufacturing
• Industrial casting machining

Headquarters

HQ city

Milwaukee

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

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

Revenue model

1. Custom Sand Casting Services: Badger Alloys generates revenue through custom sand casting manufacturing services. They pour castings ranging from 10 to 4,000+ pounds in over 200 different alloys. Revenue is project-based with custom quotes for each order. They also offer related services including pattern making, machining, engineering, and rapid response technologies.

Pricing tiers

Go-to-market motion1 record

Distribution channels1 record

Marketing channels5 records

Core offering

Badger Alloys is a full-service sand casting foundry that pours castings from 10 to 4,000+ pounds in over 200 alloys using an airset no-bake molding process. Services span pattern making, sand casting, machining, foundry engineering, rapid response technologies (robotic patternless molding and 3D-printed molds), and quality assurance/testing, all delivered from a single Milwaukee manufacturing campus. The company also offers six alloy families (high alloy/stainless steel, bronze and copper-base, brass, carbon/low alloy steels, nickel-base, and wear-resistant) supported by an interactive Alloy Search tool.

Product overview

Badger Alloys is a family-owned, full-service sand casting foundry offering a unified manufacturing platform with integrated services spanning from pattern making through finished machined castings. The core offering comprises six interconnected services: Sand Casting (using airset no-bake molding, 10-4,000+ lbs capacity, 200+ alloys), Pattern Making (traditional and robotic/3D-printed), Casting Machining (up to 10,000 lbs), Sand Casting Engineering (solidification analysis, reverse engineering), Rapid Response Technologies (robotic molding, 3D printing, prototyping), and Quality Assurance/Testing (chemical, mechanical, NDT). The company also offers 200+ alloy materials across six categories (High Alloy/Stainless Steel, Bronze/Copper-base, Brass, Carbon/Low Alloy Steels, Nickel-base, Wear-resistant), plus an Alloy Search Tool for material selection. This single-source capability enables customers to receive completed castings from concept through finished product on one Milwaukee campus.

Differentiator

Problem solved

Functional benefit

Products and services

• Sand Casting Full-service sand casting manufacturing using an airset no-bake molding process with chemical binders. Capabilities range from 10 to 4,000+ pounds, with induction melting up to 6,000 pounds and 200+ alloys poured on site for industrial OEM customers.
• Pattern Making On-site pattern making service offering custom wood, polyurethane, or metal patterns, CNC wood and urethane pattern construction, robotically milled sand molds, 3D-printed plastic patterns, and secure 45,000 sq ft pattern storage.
• Casting Machining On-site machining service for sand castings including keyway machining up to 4.5 x 40 inches, milling, turning, and dynamic balancing up to 6,500 lbs, using equipment such as the Hyundai Vertical Turning Lathe for castings up to 88 inches diameter, 7 feet tall, and 10,000 lbs.
• Sand Casting Engineering Foundry engineering services from a team with combined 80 years of experience, including MAGMASOFT solidification modeling, 3D modeling and printing, scanning, reverse engineering, and process and materials consultation for prototype castings.
• Rapid Response Technologies Next-generation manufacturing service offering robotic patternless molding with a KUKA Quantec six-axis robot, 3D-printed sand molds and cores, 3D scanning via FARO arm and Creaform HandySCAN 700 Elite, and prototype casting with mold sizes up to 8'x8' and castings up to 4,000 lbs.
• Quality Assurance and Testing Comprehensive in-house quality and testing including chemical analysis (Spectro SpectroMaxX, SciAps Z-902), mechanical testing (tensile, Charpy impact, hardness), metallographic analysis, non-destructive testing (visual, liquid penetrant, magnetic particle, radiography, ultrasonic), and sand testing.
• High Alloy/Stainless Steel Casting Materials More than 60 different high alloy and stainless steel alloys including CF8M (316), CF8 (304), CF3M (316L), CD4MCuN (Ferralium 255), and CD3MN (2205); covers austenitic, martensitic, duplex, heat-resistant, and precipitation-hardened stainless grades.
• Bronze and Copper-base Casting Materials Bronze and copper-base alloys including C95800 (C63000), C96400 (C71500), C87600, C95500 (C63020), C95200 (C61300), copper-nickel, nickel-aluminum bronze, and various tin bronzes.
• Brass Casting Materials Brass alloys including silicon brass (C87500/C69410) popular for corrosion resistance in brine applications, particularly for marine industry impellers.
• Carbon/Low Alloy Steel Casting Materials Carbon and low alloy steels including alloy steels, low-carbon, medium-carbon, and tool steels such as WCB (1025), SC8620 (8620), SC4140 (4140), LC2, and SC4330 (4330); over 40 types available.
• Nickel-base Casting Materials Nickel-base alloys including M30C, M35-1, CW12MW, CZ100 (Ni-200), CW6MC, Hastelloy variants, and Inconel variants, known for high strength, toughness, and resistance to mineral and organic acids and salts.
• Wear-resistant Casting Materials Wear-resistant alloys including Ni-Hard 1, HC-250, Stellite 6, 15% Cr-Mo, and CF10SMnN (Nitronic 60), offering resistance to oxidation and impacts of high-sulfur flue gas.

Quantifiable outcome

• Lead time reduction up to 70% with robotic patternless molding
• +5 more outcomes

Named customers4 records

Segments7 records

Ideal customer profiles4 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature7 records

Partnerships

One partnership is on record.

• FlowservecoreStrategic or Co-development PartnerFlowserve is a strategic partner for Badger Alloys, utilizing their technical advancements in castings production including 3D printing and robotic molding. Flowserve's Supplier Development Manager stated: 'We partner with Badger Alloys because they offer technical advancements in castings production. Their utilization of 3D printing and robotic molding has been a great solution for Flowserve to reduce time and capital.' The partnership allows Flowserve to choose between traditional tooling and next-gen technologies based on each project.

Scale indicators6 records

Recent moves7 records

Expansion highlights5 records

Direct peers

• Stainless Foundry & Engineering: Milwaukee-based ferrous and nonferrous foundry specializing in high-alloy, stainless, and corrosion-resistant castings with in-house pattern, machining, and NDT capabilities. Directly comparable in geography, end markets (pumps, valves, defense), and single-source service model.
• Plymouth Foundry: Midwest-based iron and steel sand casting foundry serving industrial OEM customers with patterns, castings, and machining. Comparable in size, geographic footprint, and project-based custom casting focus.
• MetalTek International: Multi-alloy US foundry group offering sand, investment, centrifugal, and continuous castings in stainless, copper, aluminum, and specialty alloys. Closest direct peer to Badger in terms of alloy breadth, custom-engineered castings, and integrated machining/pattern capabilities.
• Dotson Iron Castings: Family-owned US iron and steel sand casting foundry with in-house pattern shop, machining, and NDT services. Comparable in ownership profile, integrated single-site model, and focus on industrial OEM customers.
• Citation Castings: Brass, bronze, copper, and nickel-aluminum bronze sand casting foundry with on-site machining and pattern capabilities. Highly comparable in nonferrous alloy focus, marine/impeller applications, and custom short-run casting model.
• Sivyer Steel Castings: Midwest steel foundry producing carbon, low-alloy, and stainless steel castings with full machining and NDT services. Comparable in ferrous alloy focus, machined casting offerings, and industrial customer base.
• Progress Casting Group: Iron and steel sand casting foundry producing complex, machined, and assembled cast components for pumps, valves, and industrial OEMs. Similar end-market mix and integration of casting with machining and assembly.
• Lebanon Foundry: Iron and steel sand casting foundry offering pattern making, machining, and engineering services for industrial OEM customers. Similar mid-size custom foundry profile with comparable integrated service offering.

Broad incumbents

• Grede Holdings: Large US producer of iron, steel, and ductile iron castings serving automotive, commercial vehicle, and industrial markets. Overlaps with Badger in ferrous casting and machining, but operates at significantly higher scale and volume.
• Waupaca Foundry: Largest US iron foundry with multiple plants producing high-volume ductile and gray iron castings for automotive and industrial customers. Operates in the same end markets but at much higher volume and scale, with a less specialized alloy mix.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights7 records

Customer concentration

• LinkedInlinkedin.com/in/rob-cowen-21b7903
• Xx.com/badgeralloys
• Facebookfacebook.com/badgeralloys

Compliance9 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles6 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 Badger Alloys