Casting & tooling design
We design the raw casting and the tooling to make it in SolidWorks — reverse-engineering from your finished-part model or 2D drawings.
50–400 lb
casting weight
Gray & ductile iron · Richmond, Virginia
Production iron castings, engineered to be made right.
Gray and ductile iron, 50–400 lb. We design the casting and the tooling in SolidWorks, choose the most economical way to make it, and pour it in our Richmond foundry.
Gray & ductile
A48 · A536 iron
10k–200k lb
annual program / part
Richmond, VA
design to finished casting
Capabilities
Casting design and production, under one roof.
We pair traditional pattern and no-bake mold work with advanced 3D CAD, laser scanning and 3D sand printing — and choose the combination that makes your part for the least money.
Tooling strategy
Hard tooling, a hybrid of hard tooling and 3D-printed cores, or a full printed mold. We pick the one your volume and geometry actually pay for.
Phenolic urethane no-bake
Resin-bonded PUNB sand molding to 42″ × 72″ — dimensionally stable for heavy, detailed production castings.
Induction melt & chemistry
Induction-melted gray (A48) and ductile (A536) iron, with chemistry verified on every heat before we tap.
In-house testing
Tensile and Brinell hardness testing in-house — castings certified to ASTM specs, no outside lab.
Machining coordination
Turnkey machined castings through machine shops we’ve worked with for years — finished to your print.
Cast in Richmond
Our name goes on the iron we pour.
Every casting we make is one we’ll stand behind.
Selected work
From a prototype to a production run.
We reverse-engineer the raw casting, prove it, then pour it. Three castings documented end to end — the full set is on the Work page.
Reverse-engineeredRecasting a broken elevator cable reelGray iron · from a failed partRecast from a broken original — a grooved drum on a spoked hub, back in service.View the casting 
Design demonstrationReproducing a 1912 Velie engine blockGray iron · 3D-printed sand moldsOne corroded original, reverse-engineered in CAD and recast through 3D-printed sand molds.View the casting 
Customer projectAmerican LaFrance T-head cylinder blockGray iron · 3D-printed sand moldsA four-cylinder fire-engine head modelled in 3D CAD from an original, then poured as a run of six.View the casting 
How it’s made
From a CAD model to a finished casting.
We detail the casting ourselves — there are no simple rules for which geometry casts cleanly. Bring the part; we make it castable, then pour it.
01
Design & tooling
Reverse-engineer the raw casting in SolidWorks; cut the pattern or print the cores.
02
Mold & core
PUNB sand molds; hard-tooled or printed cores set, and the mold closed.
03
Melt & pour
Induction-melted iron, chemistry verified, tapped at temperature and poured.
04
Shakeout
Castings break from the sand, then are cleaned and blasted.
05
Machine & ship
Finished to print through our machining partners, then shipped on your carrier.
O.K. Foundry Company · letterhead engraving, c. 1912–1930
The foundry
The family that owns the shop pours the iron.
Four generations at 1005 Commerce Road in Richmond. Continuity is the point — the same shop that designs your tooling melts and pours your castings, and will be here for the next program, and the one after that.
4th gen
family-owned
foundry
foundry
One roof
design · melt ·
mold · machine
mold · machine
Richmond
1005 Commerce
Road, VA
Road, VA
Send us your model or drawings.
We’ll tell you the most economical way to make the part, and whether casting is even the right call. The more you share up front, the faster we can quote.