Foundry Solutions and Design

Name

Foundry Solutions and Design

Legal name

Foundry Solutions & Design, LLC

Website

https://foundrysd.com

Company type

Private

Founded year

2001

Operating status

Operating

Headcount range

11–50 employees

Ownership category

akta.pro rank

Product category

Foundry Engineering Consulting & Integration

NAICS

Foundries (3315)

SIC

Metalworkg Machinery & Equipment (3540)

akta.pro primary industry

Metals & Steel Mill Facility Construction (IMAFADAF)

Keywords

• Foundry engineering consulting
• Metalcasting plant design
• Foundry project management
• Greenfield foundry construction
• Foundry process simulation

Headquarters

HQ city

Alpharetta

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Services

Cost components

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

Revenue model

1. Engineering and Consulting Services: Professional services revenue generated through providing foundry engineering consulting, project management, construction coordination, feasibility studies, operational assistance, and plant design services to metalcasting businesses worldwide.

Go-to-market motion1 record

Distribution channels1 record

Marketing channels2 records

Core offering

Foundry Solutions & Design provides independent foundry engineering, consulting, and project management services to metalcasting businesses worldwide. The firm delivers a comprehensive service portfolio spanning feasibility studies, plant design, equipment specification, simulation modeling, contracting management, and operational assistance for ferrous and non-ferrous foundries, without manufacturing equipment to maintain unbiased recommendations.

Product overview

Foundry Solutions & Design is a foundry engineering consulting and integration firm offering a comprehensive portfolio of services organized into three main categories: Design & Engineering (Casting Finishing, Core Production, Plant Design, Environmental, Melt Shop, Molding, Sand Plants), Project Realization (Foundry Audits and Process Evaluation, Foundry Contracting Management), and Consulting (Feasibility Studies, Operational Assistance, Simulation Modeling and System Analysis). The firm does not manufacture equipment, enabling them to provide unbiased professional services. With over 2 centuries of combined expertise and over 950 completed projects across 45+ countries, they serve as a single-source provider for ferrous and non-ferrous foundries seeking to optimize operations, reduce costs, and implement modern plant design concepts.

Differentiator

Problem solved

Functional benefit

Products and services

• Casting Finishing Services Comprehensive casting finishing solutions covering cooling, pickup systems, rough finishing, decoring, deflashing, sawing, grinding, desprue, and final finishing systems designed to optimize metal casting quality and operational efficiency for foundry operators.
• Core Production Services Core production solutions including Core Buffer/Storage Systems, Core Delivery Systems, and Automated Core Setting devices designed to maintain molding production rates for foundry operations.
• Plant Design Services Complete foundry plant design including preliminary concept engineering, detail engineering, electrical engineering controls, purchasing, expediting, cost control, scheduling and planning for new or modernized foundry facilities.
• Environmental Compliance Services Environmental compliance consulting covering evaluation of existing foundry processes, OSHA silica regulation compliance, and process control improvements to deliver clean and safe work environments.
• Melt Shop Services Melt shop engineering including specification of optimal melt processes and furnace systems (induction, cupola, electric arc, AOD, and gas-fired furnaces) for iron, steel, aluminum, copper, and specialty alloys.
• Molding Services Molding services covering all major methods including green sand molding (vertical, matchplate, tight flask), no-bake molding, lost foam, V-process, permanent mold, and investment molding for various production volumes and casting requirements.
• Sand Plants Services Sand plant engineering specializing in greensand and no-bake sand systems with focus on reclamation for cores to reduce waste, optimize productivity and sustainability.
• Foundry Audits and Process Evaluation Comprehensive foundry benchmarking and evaluation covering design capability, material control, core making, molding, melting, finishing, quality control, and environmental and safety assessments.
• Foundry Contracting Management Project management for foundry construction and modernization covering ready-to-operate new plants, retrofit of existing facilities, installation services, equipment erection, building construction, and full project coordination.
• Feasibility Studies Strategic feasibility studies analyzing current and future production requirements, process review and optimization, equipment recommendations, layout design, investment costs, ROI determination, and project time scheduling.
• Operational Assistance Services On-site operational consulting delivered by metallurgists, sand specialists, tooling engineers, and maintenance experts focusing on quality improvement, productivity increases, downtime reduction, cost reduction, and scrap reduction.
• Simulation Modeling and System Analysis Computer simulation services using discreet event and kinetic modeling to analyze casting handling, mold making, pouring, cooling, core making, parts assembly, and conveyance processes to identify bottlenecks, buffering requirements, equipment capacity, and process optimization opportunities.

Quantifiable outcome

• 70% repeat customer rate with approximately 200 foundries in North America as repeat customers
• +1 more outcomes

Named customers10 records

Segments2 records

Ideal customer profiles2 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature1 record

Partnerships

Two partnerships are on record, tiered core.

• Equipment SupplierscoreOthersFS&D works with equipment suppliers to develop right-sized efficient equipment solutions. The company specifies optimal melt processes and equipment for foundry projects including induction furnaces, cupola furnaces, electric arc furnaces, and other foundry equipment.
• Construction PartnerscoreImplementation/ SI/ Consulting PartnerBy utilizing well established and efficient partners in the construction area, FS&D provides cost competitive installation services. Partners handle equipment erection, building construction, substructures, piping, electrical interconnection, controls, foundations and floors.

Scale indicators7 records

Recent moves6 records

Expansion highlights5 records

Broad incumbents

• Danieli: Italian metals plant builder with foundry, casting, and steelmaking engineering capability. Larger and more equipment-aligned than FS&D, but competes for the same greenfield and modernization engagements globally.
• Inductotherm Group: Largest global supplier of induction melting equipment that also offers melt shop engineering and turnkey foundry services. Competes with FS&D on melt shop design and broader foundry integration.
• Primetals Technologies: Metals-industry EPC and technology provider with deep foundry, casting, and rolling-mill engineering capability. Overlaps with FS&D on plant design and project management for new metalcasting facilities but is much larger and equipment-aligned.
• SMS group: German plant-engineering and equipment manufacturer for the metals industry offering turnkey metallurgical plant design, construction, and lifecycle services. Competes with FS&D on greenfield foundry/mill engineering but bundles equipment with services.

Emerging players

• ABP Induction: Induction furnace and foundry systems supplier that also provides engineering and integration services. Comparable to FS&D on melt shop design, though it sells its own furnaces and is therefore not equipment-agnostic.
• DISA / Sinto: Original parent of the Georg Fischer/DISA joint venture from which FS&D was spun off in 2001. Equipment manufacturer that also delivers foundry plant solutions and competes with FS&D on greenfield molding line and foundry integration projects.

Direct peers

• Hatch: Global engineering consultancy with a dedicated Metals & Mining practice that designs smelters, foundries, and steel mills end-to-end. Closest direct peer to FS&D in providing independent, multidisciplinary engineering services for metalcasting facilities worldwide.
• Vulcan Engineering: North American designer and builder of foundries and casting facilities, including greenfield plant construction, equipment, and automation. Direct competitor to FS&D for greenfield and brownfield foundry projects in the U.S. market.
• Küttner: German engineering and equipment company focused on foundries and steelworks, offering engineering, process technology, and turnkey plant construction. Direct peer to FS&D in foundry plant design and project execution, though also an equipment manufacturer.
• TechSolve (AmCast): U.S. manufacturing consultancy with a dedicated metalcasting practice providing process audits, training, and engineering services to foundries. Closest U.S.-based independent consulting peer to FS&D's feasibility and operational assistance lines.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat4 records

Key risks6 records

Key highlights7 records

Customer concentration

• LinkedInlinkedin.com/company/foundry-solutions-&-design
• Xx.com/foundrysd

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 Foundry Solutions and Design