Carley Foundry
Carley Foundry is a third-generation, family-owned metal casting foundry in Blaine, Minnesota producing custom aluminum and steel castings for aerospace, defense, medical, commercial, recreational vehicle, and energy customers across six in-house casting processes.
- Company typePrivate
- Founded1955
- HeadquartersMinneapolis, United States
- Headcount101–250
- GTM typeB2B
- OfferingHardware or Manufacturing
What Carley Foundry does
Carley Foundry is a third-generation, family-owned metal casting foundry headquartered in Blaine, Minnesota, producing custom aluminum and steel castings for aerospace, military/defense, medical, commercial, recreational vehicle, and energy customers. Founded in 1955 by Frank and Lois Carley in the basement of their home, the company operates a 253,000-square-foot, four-building campus with 101-250 employees and has grown entirely through self-funded organic expansion and adjacent property acquisitions rather than external capital.
The company's technical foundation rests on six in-house casting processes — green sand molding, dry sand molding, core making, permanent molding, low-pressure permanent mold, and investment casting — supported by integrated special processes including NADCAP-accredited heat treatment, materials testing, non-destructive testing, and welding. A 16-person engineering team with 250+ combined years of experience uses Magma casting simulation software for solidification modeling, while in-house pattern making and tool design, digital radiography, and 3D printing/additive manufacturing (used for sand cores and patterns for approximately a decade with expanded usage in the past four years) round out the technical stack. Quality certifications include AS9100D and ISO 9001:2015 (both recertified in January 2024 with zero non-conformances) and NADCAP accreditation across four special processes.
Commercially, Carley Foundry operates a direct B2B enterprise field sales model with no e-commerce or marketplace presence. A dedicated sales organization — VP of Sales Kevin Stensrud, two Senior Sales Engineers, a Sales Engineer, and an Estimator — engages named enterprise customers that include Honeywell (turbofan engine components), GE Healthcare (medical imaging equipment), Allison Transmission (commercial truck powertrains), U.S. military and defense contractors (JDAM, Paveway, and Mark 84 munitions components), gas turbine manufacturers, and motorcycle OEMs. Pricing is custom-quoted per project based on specifications, alloy selection, process, volume, and complexity, with multi-year contracts; no public pricing is published. The company is privately held under Jordan Carley's ownership with no disclosed funding rounds, parent company, or planned liquidity event.
Carley Foundry firmographics
Firmographics- Name
- Carley Foundry
- Legal name
- Carley Foundry, Inc.
- Website
- https://carleyfoundry.com
- Company type
- Private
- Founded year
- 1955
- Operating status
- Operating
- Headcount range
- 101–250 employees
- Short description
- Carley Foundry is a third-generation, family-owned metal casting foundry in Blaine, Minnesota producing custom aluminum and steel castings for aerospace, defense, medical, commercial, recreational vehicle, and energy customers across six in-house casting processes.
- Ownership category
- akta.pro rank
Carley Foundry industry classification
Industry- Product category
- Metal Casting / Foundry Manufacturing
- NAICS
- Aluminum Foundries (except Die-Casting) (331524), Steel Investment Foundries (331512), Foundries (3315)
- SIC
- Iron & Steel Foundries (3320), Nonferrous Foundries (Castings) (3360)
- akta.pro primary industry
- Aluminum Casting & Ingot/Billet/Slab Production (IMAKACAE)
- akta.pro secondary industry
- Steel Casting (Continuous Casting, Ingots, Semi-Finished Slabs/Billets/Blooms) (IMAKABAD)
Keywords
Where Carley Foundry is headquartered
LocationHeadquarters
- HQ city
- Minneapolis
- HQ country
- United States
- HQ region
- North America
Offices2 records
Markets served
Carley Foundry business model
Business model- GTM type
- B2B
- Offering type
- Hardware or Manufacturing
- Cost components
- Operations, Personnel, Infrastructure, Technology or R&D, Marketing or Sales, Supply Chain
Revenue model
- Casting Services: Custom metal casting services for aluminum and steel alloys using multiple processes (green sand, dry sand, permanent mold, low-pressure permanent mold, investment casting). Services range from prototype to high-volume production runs. Castings range from several ounces to over 500 pounds.
Pricing tiers
| Model | Billing | Price |
|---|---|---|
| Other | Multi-year contract | Custom casting services - quote-based pricing |
Go-to-market motion1 record
Distribution channels1 record
Marketing channels5 records
Carley Foundry product offering
Product offeringCore offering
Carley Foundry is a full-service metal casting foundry producing premium-quality custom castings in aluminum and steel alloys for aerospace, military/defense, medical, commercial, recreational vehicle, and energy markets. Core offerings span green sand molding, dry sand molding, permanent molding, low-pressure permanent mold, and investment casting processes supported by in-house heat treatment, NDT/quality assurance, engineering with Magma simulation, rapid prototyping (3D printing), and pattern making/tool design, with castings ranging from several ounces to over 500 pounds.
Product overview
Carley Foundry is a third-generation family-owned full-service casting facility offering multiple casting processes as a unified service portfolio. The company's core offerings span three primary casting method categories: Green Sand Molding and Dry Sand Molding for flexible production runs; Permanent Molding and Low-Pressure Permanent Mold for mid-to-high volume needs; and Investment Casting for precision components. These processes are supported by integrated special processes including Heat Treatment, Quality Assurance/Quality Control, Engineering Services with Magma simulation, Rapid Prototyping using 3D printing, and Pattern Making/Tool Design. The foundry serves aerospace, military/defense, recreational vehicle, medical, commercial, and energy markets, producing castings from several ounces to over 500 pounds in aluminum and steel alloys.
Differentiator
Problem solved
Functional benefit
Products and services
- Green Sand Molding
Quantifiable outcome
- Zero non-conformances in AS9100D/ISO 9001:2015 recertification audit (2024)
- +3 more outcomes
Companies that use Carley Foundry
Customer profileNamed customers7 records
Segments6 records
Ideal customer profiles6 records
Carley Foundry technology and API
TechnologyTechnology focussed No
API detail
- Has API
- No
- API docs
- API detail
Core technology
AI maturity
App detail
Feature5 records
Carley Foundry partnerships and signals
Strategic signalScale indicators5 records
Recent moves12 records
Expansion highlights6 records
Carley Foundry competitors and assessment
Company assessmentDirect peers
- Materion Corporation: Specialty alloys and engineered materials supplier serving aerospace, defense, and medical. Comparable to Carley's higher-spec stainless and ferrous investment casting work for demanding aerospace and medical imaging customers like GE Healthcare.
- Signicast (Form Technologies): Mid-to-large U.S. investment casting foundry serving aerospace, defense, medical, and industrial markets. Comparable business model to Carley's investment casting line, with similar customer profile and NADCAP/AS9100 certifications.
- Precision Castparts Corp: Berkshire Hathaway-owned global leader in investment castings, forgings, and fasteners for aerospace and industrial markets. Closely comparable on investment casting of stainless steel and super-alloys into aerospace/defense components like turbine and structural parts.
- Howmet Aerospace: Major aerospace castings and engineered products supplier, originally spun out of Arconic/Alcoa. Directly comparable to Carley Foundry on aerospace investment castings in nickel, titanium, and aluminum alloys for jet engine and airframe applications.
- MetalTek International: Diversified non-ferrous and stainless steel foundry offering sand, investment, and centrifugal casting. Comparable to Carley in serving aerospace, defense, medical, and energy with multi-process in-house capabilities and certified quality systems.
- Aero Metals Alliance: U.S. aerospace metals manufacturer producing castings and forgings for engine and airframe applications. Comparable to Carley's aerospace-focused investment casting work for OEMs such as Honeywell.
- Grede Holdings: U.S.-based iron and aluminum foundry serving automotive, commercial vehicle, and industrial markets. Comparable to Carley's commercial and heavy-equipment casting lines, particularly drivetrain and structural aluminum components.
Regional players
- Endurance Technologies: India-based aluminum die casting and alloy wheel manufacturer for automotive and commercial vehicle markets. Comparable to Carley's aluminum permanent mold and gravity die casting capabilities but regionally focused and OEM-channel concentrated.
- Impro Industries: China-based precision investment casting and machined components supplier serving aerospace, automotive, and industrial markets. Comparable technology stack to Carley (investment casting, CNC machining) but primarily serves different geographies and OEM relationships.
Broad incumbents
- Ellwood Group: Privately held U.S. steel foundry and forge group serving heavy industrial, defense, oil and gas, and rail markets. Comparable to Carley's ferrous casting work for defense and energy applications, with broader industrial diversification and larger scale.
Market position
Strengths4 records
Weaknesses4 records
Competitive moat5 records
Key risks5 records
Key highlights7 records
Customer concentration
Carley Foundry social profiles
Digital presenceCarley Foundry compliance and trust
Trust signalCompliance3 records
Carley Foundry financial estimates
Financial estimateRevenue estimate
Valuation estimate
Carley Foundry leadership team
Management profileNumber of profiles
Profiles19 records
Carley Foundry funding detail
Funding detailFunding overview
Funding rounds
Investors
Funding detail is available on the Subscription and Enterprise plan.Contact sales →
Carley Foundry M&A and investment
M&A and investmentM&A
Investments
M&A and investment is available on the Subscription and Enterprise plan.Contact sales →
Frequently asked questions about Carley Foundry
What does Carley Foundry do?
Carley Foundry is a full-service metal casting foundry producing premium-quality custom castings in aluminum and steel alloys for aerospace, military/defense, medical, commercial, recreational vehicle, and energy markets. Core offerings span green sand molding, dry sand molding, permanent molding, low-pressure permanent mold, and investment casting processes supported by in-house heat treatment, NDT/quality assurance, engineering with Magma simulation, rapid prototyping (3D printing), and pattern making/tool design, with castings ranging from several ounces to over 500 pounds.
Is Carley Foundry a public or private company?
Carley Foundry is a private company. It is classified as family owned and is currently operating.
When was Carley Foundry founded?
Carley Foundry was founded in 1955. It employs 101 to 250 people.
Where is Carley Foundry based?
Carley Foundry is headquartered in Minneapolis, United States, in the North America region.
How does Carley Foundry make money?
One revenue line is on record: casting Services.
Who are Carley Foundry's main competitors?
Direct peers on record are Materion Corporation, Signicast (Form Technologies), Precision Castparts Corp, Howmet Aerospace, MetalTek International, Aero Metals Alliance and Grede Holdings. Regional players are Endurance Technologies and Impro Industries. Ellwood Group is listed as a broad incumbent.
Does Carley Foundry have an API?
No public API is recorded for Carley Foundry.
What industry is Carley Foundry in?
Carley Foundry's product category is Metal Casting / Foundry Manufacturing. Its primary akta.pro industry code is IMAKACAE, Aluminum Casting & Ingot/Billet/Slab Production, with a secondary code of IMAKABAD, Steel Casting (Continuous Casting, Ingots, Semi-Finished Slabs/Billets/Blooms). Its NAICS code is 331524 and its SIC code is 3320.