O'Fallon Casting

What O'Fallon Casting does

O'Fallon Casting is a privately-held, family-owned investment casting foundry operating from a single 75,000-square-foot facility at 600 Cannonball Lane in O'Fallon, Missouri, since 1969. The company specializes in the manufacture of complex, thin-walled aluminum investment castings using alloys such as 356, A356, C355, A357, and F357, and is the self-described preeminent global manufacturer of Investment Cast Aluminum/Silicon Carbide Metal Matrix Composite (MMC) castings, with Silicon Carbide particles (9-38 microns) homogeneously suspended in an aluminum matrix at 20%-40% SiC by volume.

The core production process is supported by a full in-house engineering stack: ProCAST solidification modeling for thermal and gating simulation, in-house 4-axis and 5-axis CNC tool design and machining (added in 2020), Digital Radiography on a Northstar X5000 system (digital capability since 2008, NADCAP-compliant since 2020), and Digital Product Definition with non-contact laser scanning inspection. Surrounding the casting operation, O'Fallon offers Design for Manufacture and Concurrent Engineering services, IC-101 and IC-201 customer education classes, rapid prototype casting directly from customer CAD files, and a Complete to Print turnkey service that manages qualified subcontractors for secondary operations including machining, EDM, coatings, assembly, and product testing.

The company serves Aerospace, Defense, Medical, and Commercial end markets from a single U.S. foundry, distributing exclusively through a direct enterprise sales motion staffed by Sales Engineers. Quality accreditation comprises ISO 9001, AS9100 (valid through 2028), and NADCAP certifications for Non-Destructive Testing, Heat Treating, and Welding, with DFARS compliance supporting defense work. Pricing is quote-based and not publicly disclosed; Concurrent Engineering and IC-101 classes are provided free to customers as a design-in mechanism, while castings and turnkey services are billed per project, often under multi-year contracts.

Name

O'Fallon Casting

Legal name

O'Fallon Casting

Website

https://ofalloncasting.com

Company type

Private

Founded year

1969

Operating status

Operating

Headcount range

101–250 employees

Short description

O'Fallon Casting is a family-owned U.S. investment casting foundry, established 1969, that manufactures complex thin-walled aluminum and Al/SiC metal matrix composite castings for aerospace, defense, medical, and commercial customers from its single O'Fallon, Missouri facility.

Ownership category

akta.pro rank

Headquarters

HQ city

O Fallon

HQ country

United States

HQ region

North America

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

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

Revenue model

1. Investment Casting Sales (Aluminum and MMC): Core revenue stream from the manufacture and sale of aluminum alloy and Al/SiC Metal Matrix Composite investment castings to Aerospace, Defense, Medical, and Commercial customers. Includes standard castings as well as Rapid Prototype Castings produced directly from customer CAD files.
2. Complete to Print (Turnkey) Services: O'Fallon Casting offers post-cast secondary services such as machining, EDM, coatings, assembly, and product testing. O'Fallon engages and administrates sub-tier purchase orders with qualified subcontractors to deliver turnkey finished products compliant with customer contract requirements.
3. Design for Manufacture / Concurrent Engineering: Engineering services including Concurrent Engineering, IC-101 and IC-201 classes, and the Aluminum Investment Casting Design Guide. Concurrent Engineering is provided free to customers, functioning as a value-add engagement that drives specification of O'Fallon castings.

Pricing tiers

Go-to-market motion2 records

Distribution channels2 records

Marketing channels6 records

Core offering

O'Fallon Casting manufactures complex, thin-walled aluminum and aluminum/silicon-carbide metal matrix composite (MMC) investment castings for aerospace, defense, medical, and commercial customers from its single 75,000-square-foot foundry in O'Fallon, Missouri. Its offering spans core casting (alloys 356, A356, C355, A357, F357 and specialty Al/SiC MMC at 20-40% SiC), complemented by Rapid Prototype Castings from CAD, Complete to Print turnkey finishing, in-house tooling, multi-axis CNC machining, ProCAST solidification modeling, Digital Radiography, and Digital Product Definition/laser-scanning inspection. Concurrent Engineering and IC-101/IC-201 training are provided free to customers to drive design-in of O'Fallon castings.

Product overview

O'Fallon Casting is a single unified investment casting foundry offering a portfolio of interrelated production and engineering services rather than a platform-plus-modules software product. Its core offering is Aluminum Investment Castings (alloys such as 356, A356, C355, A357, F357) complemented by the specialty Al/SiC Metal Matrix Composite (MMC) product line. The portfolio surrounds these core castings with supporting services: Rapid Prototype Castings (CAD-direct prototyping), Complete to Print (turnkey post-cast subcontract management), Design For Manufacture (Concurrent Engineering, IC-101, IC-201, and the Aluminum Investment Casting Design Guide), Solidification Modeling (ProCAST-based simulation), Digital Radiography (Northstar X5000), Tool Design & Construction (4-axis and 5-axis machining), Digital Product Definition (DPD), and Non-Contact Inspection (laser scanning). Together these capabilities let customers move from design through prototype, tooling, cast, secondary operations, and inspection under one aerospace- and defense-accredited supplier.

Differentiator

Problem solved

Functional benefit

Products and services

• Aluminum Investment Castings Casting of aluminum alloys (most commonly 356, A356, C355, A357, F357) into complex, thin-walled parts for aerospace, defense, and medical industries. Represents the largest portion of O'Fallon Casting's business.
• Al/SiC Metal Matrix Composite (MMC) Castings Investment cast Aluminum/Silicon Carbide Metal Matrix Composites with 20%-40% SiC particle volume (9 to 38 microns). Produces near-net shapes with high thermal conductivity, low CTE, high stiffness, and vibration dampening, mimicking cast Beryllium Aluminum without the health hazard.
• Rapid Prototype Castings Small-quantity prototype castings manufactured directly from a customer-supplied CAD file. Supports reduced time-to-market, design mock-up, qualification, and low-rate manufacturing with fine surface finish and dimensional precision comparable to hard-tooled parts.
• Complete to Print Turnkey service in which O'Fallon Casting engages and administrates sub-tier purchase orders with qualified subcontractors for secondary operations including machining, EDM, coatings, assembly, and product testing, delivering a completed product compliant with customer contract requirements.
• Design For Manufacture (DFM) Concurrent Engineering and design education services including IC-101 classroom sessions, IC-201 hands-on foundry classes, and the Aluminum Investment Casting Design Guide, helping customers avoid designed-in costs and achieve first-time-best design.
• Solidification Modeling Simulation of thermal conditions during the investment casting process using ProCAST software to develop gating and assembly techniques that produce compliant parts economically, outputting filling temperature, fraction solid, shrinkage porosity, hot spots, and dendrite arm spacing.
• Digital Radiography Captures X-ray images digitally, eliminating film. Performed on a Northstar X5000 system that meets NADCAP digital x-ray requirements, simplifying storage and retrieval of inspection records.
• Tool Design & Construction In-house tooling engineering and toolmaking including new tool design, new tool construction, repair and qualification of customer-supplied tooling, and maintenance of current tooling inventory, supported by 4-Axis Vertical and 5-Axis Machining Centers.
• Digital Product Definition (DPD)

Segments4 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

Scale indicators7 records

Recent moves4 records

Expansion highlights4 records

Broad incumbents

• Howmet Aerospace: Howmet Aerospace is a large, publicly traded aerospace supplier with a substantial aluminum investment casting business (engine and airframe components). It is a broad incumbent competitor in the same aerospace nonferrous casting category where O'Fallon competes, but operates at materially larger scale across many programs and geographies.
• Precision Castparts Corp. PCC (a Berkshire Hathaway company) is one of the world's largest investment casting producers for aerospace and industrial gas turbine markets. It overlaps directly with O'Fallon's aerospace investment casting work but at vastly greater scale and with broader ferrous and superalloy capabilities.

Direct peers

• Signicast: Signicast is a US investment casting foundry offering both ferrous and nonferrous (aluminum) investment castings to aerospace, defense, medical and industrial customers. It is a direct peer to O'Fallon in nonferrous investment casting, with comparable Complete to Print and engineering services.
• Hitchiner Manufacturing: Hitchiner is a US investment casting foundry specializing in near-net-shape complex castings for aerospace, defense and industrial customers using both ferrous and nonferrous alloys. It directly competes with O'Fallon in complex, thin-walled aerospace investment castings and shares a similar engineering-services-led GTM motion.
• Milwaukee Precision Castings: Milwaukee Precision Castings is a US-based nonferrous investment casting foundry serving aerospace, defense and commercial customers. It is a direct, similarly sized peer to O'Fallon, focused on complex aluminum and specialty alloy investment castings with NADCAP-accredited NDT and machining.
• Concast Metal Products Co. Concast is a US continuous-cast and investment casting producer of copper and aluminum alloys serving industrial, aerospace and defense markets. It is comparable to O'Fallon as a nonferrous specialty caster, though more weighted toward copper-based alloys.
• Barron Industries: Barron Industries is a US investment casting foundry producing ferrous and nonferrous castings (including aluminum) for aerospace, defense and industrial customers with in-house machining and NDT. It is a direct peer to O'Fallon in the small-to-mid US investment casting segment with similar aerospace and defense orientation.
• Metaltek International: Metaltek International is a US metal casting group (including investment casting) serving aerospace, defense, petrochemical and industrial markets. It is comparable to O'Fallon as a multi-process specialty foundry with aerospace and defense certifications, though with broader alloy and process coverage.

Regional players

• CIREX Castings: CIREX is a Netherlands-based investment casting foundry specializing in complex steel and nonferrous investment castings for European industrial and aerospace customers. It is a regional peer with comparable technology and customer profile but does not directly compete in O'Fallon's primary North American aerospace/defense base.
• Impro Industries: Impro Industries is a China-headquartered global investment casting and machining supplier serving aerospace, automotive and industrial customers. It is a regional competitor with overlapping nonferrous investment casting capability but serves primarily Asia- and Europe-based OEMs rather than O'Fallon's North American aerospace/defense core.

Market position

Strengths4 records

Weaknesses4 records

Competitive moat5 records

Key risks6 records

Key highlights6 records

Customer concentration

• YouTubeyoutube.com/watch?v=0pdsML1GMN0

Compliance5 records

Revenue estimate

Valuation estimate

Number of profiles

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 O'Fallon Casting