Partner with Badger Foundry iron casting suppliers in Winona, MN, for quality casts backed by three generations of industry-leading craftsmanship. When it comes to large, complex casts, we are the best in what we do.

Badger Foundry Parts Stored On Wooden Pallets
A Badger Foundry Iron Casted Part
Iron Castings Made By Badger Foundry Stacked On Top Of Each Other With Plywood Separating Them

Gray Iron Castings

  • Class 30, 35 & 40 Iron

  • All grades are compliant to ASTM A48 Standards, we are also capable of producing specialty blends.

  • Castings from 100 to 4,500 lbs

  • Melt capacity of 50 tons/day

Several Large Metal Pipes Are Stacked On Pallets.
A Large Metal Machine Part On A Table At Badger Foundry
A Close Up Of A Metal Object On A Table.

Ductile Iron Castings

  • Ductile Iron Grades: 60-40-18, 65-45-12, 80-55-06, and 100-70-03

  • All grades compliant with ASTM A536, we are also capable for producing specialty blends.

  • Castings from 100 to 2,500 lbs

  • Melt capacity of 20 ton/day

Two Men Working In Badger Foundry On Assembly Line
Two Men Working In Badger Foundry Hammering Something
Badger Foundry Part Mold
Two Men Working In Badger Foundry Applying Coating.
A Man Is Working On A Large Mold At Badger Foundry

Core Make

  • No-Bake cores in excess of 3000 pounds

  • Complex Core Design and Assembly

  • Proprietary blends to accommodate customer needs

Two Badger Foundry Employees Working On The Factory Floor.
Two Men Working In A Factory With Machinery.
Badger Foundry Employee Pouring Melted Metal Into A Mold.

Molding Processes

Badger Foundry maintains two independent molding process to assist our customers needs.  The Green sand system is designed with 3 horizontal parted molding machining’s (cope / drag).  Flask size ranging from 20×24 inches up to 30×62 / 40×40 inches.   Our green sand molding expertise provides a cost-effective solution for the precise castings of complex components up to 1000 lbs. Sand properties are managed with Sand Lab test and an automated Hartley Control System, which tests every batch of sand for desired properties.  .

The No-Bake process is made up of two mixers which supports three lines.  This system is developed with a chemically bonded sand and used for larger and more intricate castings. Our no-bake molding services accommodate components up to 4000 lbs with custom-designed flasks reaching up to 80×100 inches.

Closeup Of Molten Metal Being Poured.
A Worker Is Working On A Metal Object In Badger Foundry.

Melt

Badger Foundry maintains two primary melting sources (Cupola and Electric Furnace).   Extensive process controls and chemistry analysis  are performed by our in-house Metallurgical lab. Our primary equipment is a spectrometer (17 elements) and a Leco for Carbon and Sulfur.  Each job is specifically identified on process cards as to chemistry, alloy requirements, pour temperature and hold times.  This detailed requirement allows each job to be specifically managed for metallurgical properties. We pride ourselves on the quality of our iron and maintain detailed records on each pour.

Badger Foundry Employee Working On A Product
A Badger Foundry Employee Is Working On A Large Circular Iron Product In The Factory
Badger Foundry Employee Working On A New Part

Cleaning Room

  • Three Hanger Blast Machines

  • One Tumble Blast Machine

  • Large Cast Grind work cells

  • Small Cast Grind work cells

  • Small Cast Inspection work cells

  • Small Cast Final Inspection cell

Value Added Assemblies

Badger Foundry maintains a high quality supplier base to offer Tier 1 Supplier services. Supplier Approval Process, detailed specifications, financial strength and dedicated working relationships are some of the critical aspects of Tier 1. Primary Tier 1 activities are Paint, Heat Treat, Machining, and assembly.