Rheocast Company

What Rheocast Company does

Rheocast Company is a U.S. contract manufacturer specializing in high-pressure brass and aluminum die castings, founded in 1977 and operating from a 30,000 sq ft die casting facility plus a 15,000 sq ft machining and value-added services facility in Germantown, Wisconsin. The company is a division of family-owned The Fall River Group, Inc., led by CEO Brennen Weigel, with Charlie Wright Jr. serving as VP of Operations. Its core technology is cold chamber high-pressure die casting for brass alloys (C85700, C85800, C87500, C87800, C99750) and aluminum alloys (A360, A380, A383, A413, Silafont 36, Mercalloy 368), with proprietary Cast In-Place Technology for embedding heating elements and inserts into pressure-tight brass assemblies rated to 300 psi. The company operates 500-900 ton die casting machines, including an 800-ton HPM press, with in-house tooling, CNC machining, finishing, assembly, CMM-based inspection, and ISO 9001:2015 certified quality systems.

Name

Rheocast Company

Legal name

Rheocast Company

Website

https://rheocast.com

Company type

Private

Founded year

1977

Operating status

Operating

Headcount range

11–50 employees

Short description

Rheocast Company is a U.S. contract manufacturer founded in 1977 specializing in cold chamber high-pressure brass and aluminum die castings for OEM customers across fluid metering, security hardware, medical, HVAC, transportation, and industrial markets.

Ownership category

akta.pro rank

Headquarters

HQ city

Germantown

HQ country

United States

HQ region

North America

Offices3 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

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

Revenue model

1. Contract Manufacturing - OEM Die Castings: Contract manufacture of high-pressure brass and aluminum die castings for OEMs. Revenue generated from production of custom die-cast components with supporting services including tooling, machining, finishing, and assembly. Services approximately 80% of castings receive secondary operations.
2. Value-Added Services: Additional revenue from tooling design and construction, CNC machining, finishing, assembly, and inventory management services. Flexible inventory options including JIT, KANBAN, consignment, and custom plans.

Pricing tiers

Go-to-market motion2 records

Distribution channels2 records

Marketing channels5 records

Core offering

Rheocast Company is a U.S. contract manufacturer specializing in cold chamber high-pressure die castings of brass and aluminum alloys for OEM customers. The company produces components weighing from less than 1 ounce to more than 10 pounds, supported by complete in-house services including CAD engineering, tooling design and construction, CNC machining, finishing, assembly, and flexible inventory management (JIT, KANBAN, consignment). It operates from a 30,000 sq ft die casting facility plus a 15,000 sq ft machining and value-added services facility in Germantown, Wisconsin.

Product overview

Rheocast Company is a premier American contract manufacturer of high-pressure die castings, founded in 1977. The company operates as a division of The Fall River Group and specializes in two core products: Brass Die Casting and Aluminum Die Casting, both produced using cold chamber high-pressure die casting processes. These core offerings are supported by a comprehensive suite of value-added services including In-House Tooling (tooling design and construction), CNC Machining, Finishing Services, Assembly Services, Quality Testing and Inspection, Flexible Inventory Management, Industrialization and Prototyping, and CAD Engineering. The company also offers a proprietary Cast In-Place Technology for embedding inserts into pressure-tight brass assemblies. Products range from less than 1 ounce to 10 pounds, serving diverse industries including automotive, transportation, fluid metering, plumbing, security hardware, and industrial applications. The company holds ISO 9001:2015 certification and operates from a 30,000 square foot die casting facility plus 10,000 square feet of manufacturing and machining space in Germantown, Wisconsin.

Differentiator

Problem solved

Functional benefit

Products and services

• Brass Die Casting High-pressure brass die casting service using cold chamber machine processing. Produces corrosion-resistant, pressure-tight components up to 300psi with excellent electrical conductivity and attractive decorative finishes, suitable for OEM applications requiring rugged durability. Standard tolerance +/- 0.010 inches; alloys include C85700, C85800, C87500, C87800, C99750.
• Aluminum Die Casting Cold chamber aluminum high-pressure die casting service producing lightweight, strong, corrosion-resistant components. Specializes in A360, A380, A383, A413, Silafont 36, and Mercalloy 368 alloys. Standard tolerance +/- 0.005 inches; minimum wall thickness 0.045 inches.
• High Pressure Die Casting Core manufacturing process using die casting machines (500 to 900 tons, including an 800-ton HPM press) to inject molten metal under considerable pressure into steel molds. Produces complex shapes with exceptional accuracy and repeatability, suitable for aluminum and brass components ranging from less than 1 ounce to 10 pounds.
• Cast In-Place Technology Proprietary technology that casts heating elements or other types of inserts directly into pressure-tight brass assemblies during the die casting process, eliminating secondary assembly operations for embedded components.
• In-House Tooling Complete tool room services including tooling design, construction, cleaning, and maintenance for high-pressure brass and aluminum die casting. Climate-controlled facility equipped with CNC machines, grinders, lathes, CMM, and EDM equipment.
• CNC Machining Precision CNC machining services including lathes, mills, and surface grinders for secondary operations on die cast components.
• Finishing Services Surface finishing services including polishing, coating, vibratory de-burring, grit-blast finishing, and painting for smooth or textured die casting surfaces.
• Assembly Services Complete assembly services for die cast components, including custom automation and assembly equipment produced in-house or through parent company Fall River Foundry.
• Quality Testing and Inspection Comprehensive inspection services including Coordinate Measuring Machine (CMM), optical comparator, hardness testing, pressure testing, tensile testing, and spectrometer chemical analysis, governed by an ISO 9001:2015 certified quality management system.
• Flexible Inventory Management Inventory management programs including Just-in-Time (JIT), KANBAN, consignment, carry-in-stock, and custom inventory plans to meet customer-specific supply requirements.
• Industrialization and Prototyping Product design finalization services using actual die-cast parts with single-cavity prototype tooling, supporting rapid industrialization of new components for OEM customers.
• CAD Engineering Full-service CAD engineering support for product design optimization, value engineering, and tooling design for high-pressure die casting applications.

Quantifiable outcome

• 83% reduction in machining time, casting weight, and assembly time when converting sand casting to die casting
• +4 more outcomes

Named customers8 records

Segments6 records

Ideal customer profiles2 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature4 records

Partnerships

Four partnerships are on record, tiered core, flagship and minor.

• ITL Machinery ServicescoreTechnology or Integration · 17 April 2017ITL Machinery Services in Marion, Ohio completely remanufactured the HPM Model D-800 die casting machine with advanced technology. Machine features Allen-Bradley 5/05 processor control and tie bar tonnage indicators.
• Visitrak WorldwidecoreTechnology or Integration · 17 April 2017Integrated Visitrak Worldwide's Total Trak system for shot monitoring and control on the HPM D-800 die casting machine. HMI interface allows adjustment of clamp and shot pressures and reading of tie bar tonnages.
• Fall River Foundry / The Fall River GroupflagshipStrategic or Co-development PartnerParent company relationship. Fall River Foundry is a Bronze and Aluminum Green Sand Cast Foundry located in Fall River, Wisconsin. Rheocast leverages Fall River Foundry's engineering and tooling resources. Shared leadership under President and CEO Brennen Weigel. Fall River Group encompasses multiple manufacturing divisions.
• Prairie States EnterprisesminorOthersIndependent third party administrator of a self-funded health plan for The Fall River Group, Inc. Provides transparency in coverage compliance services for health benefits.

Scale indicators8 records

Recent moves7 records

Expansion highlights5 records

Direct peers

• Dynacast: Global precision die caster (part of Form Technologies) producing high-pressure die castings in aluminum, zinc, and magnesium for OEM customers across industrial, automotive, and consumer end-markets. Directly comparable because it competes head-on with Rheocast in custom engineered die cast components for industrial OEMs.
• Pace Industries: One of the largest North American die casting companies operating multiple aluminum, magnesium, and zinc die casting facilities. Comparable to Rheocast as a multi-site contract die caster serving industrial, automotive, and consumer OEM customers with similar value-added services.
• Chicago White Metal Casting: High-pressure aluminum and zinc die casting manufacturer serving industrial OEMs from the U.S. Midwest. Directly comparable to Rheocast because it provides custom-engineered die cast components with CNC machining, finishing, and assembly to overlapping Midwest industrial customers.
• Citation Die Casting: Custom aluminum high-pressure die casting supplier to OEMs in industrial and commercial markets. Comparable to Rheocast because of its focus on custom-engineered castings with value-added machining and finishing for OEM customers.
• Premier Die Casting Company: Custom high-pressure aluminum and zinc die casting manufacturer serving industrial OEM customers. Comparable to Rheocast because of similar custom-engineered die casting capability and OEM contract-manufacturing model.

Regional players

• Wisconsin Die Casting: Wisconsin-based aluminum and zinc die caster offering custom high-pressure die castings and value-added services. Comparable to Rheocast as a regional Midwest peer competing for similar industrial OEM business in the same geography.

Broad incumbents

• Shiloh Industries: Larger, multi-plant supplier of aluminum, magnesium, and steel die cast and stamped components, primarily for automotive OEMs. Comparable to Rheocast in die casting technology and OEM focus, but at much greater scale and with deeper automotive concentration.
• Gibbs Die Casting Group: Long-established U.S. aluminum high-pressure die caster supplying Tier-1 automotive and industrial OEMs. Comparable to Rheocast in core high-pressure die casting process and OEM contract-manufacturing model, though it operates at meaningfully larger scale.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights6 records

Customer concentration

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• LinkedInlinkedin.com/company/rheocast

Compliance1 record

Revenue estimate

Valuation estimate

Number of profiles

Profiles3 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 Rheocast Company