8 Things to Look for in a Stainless Steel Casting Foundry
Whether you are looking to cast a part for the first time or move production of a time-tested staple of your business, choosing a foundry can be, in a word, frustrating. Foundries may dot the map, but getting the stars to align on turnaround times, expertise, cost, and capabilities can feel like herding cats. However, taking the time to get it right can be the difference between making or breaking a product launch or having a solid reputation versus expensive recalls.
At IPC Foundry Group, we understand how critical it is to choose a precision casting foundry that will work with you to nail your production cycles. In this article, we'll cover eight key factors in finding a foundry that is a perfect fit for your project.
Let's get into it.
Choosing a quality foundry can save your business money and frustrations
1) Capabilities: Can they do it?
This is unequivocally the most crucial factor in selecting a foundry for your stainless steel castings.
Here are just a few things to consider:
Is the foundry able to match the needs of your project?
Do they have the ability to pour your alloy?
Can they handle the volume of parts?
Can they successfully cast any complex geometry on your part? Have they cast a similar project in the past?
When seeking out a foundry, these should be some of the first benchmarks to ask about because if they can't successfully cast your project, nothing else matters.
You can think of your search for a foundry as similar to hiring a new staff member. It doesn't matter how personable the candidate is or how stellar their letters of recommendation are if they do not have the requisite skills for the job at hand.
These capabilities should be pretty easy to gauge while speaking with them, and how they communicate with you can be a solid indicator of how your partnership will function; more on that in our next point.
2) Open Communication
A painfully familiar experience of my twenties is what I call the "I'm on the way, while still on the couch" syndrome. We’ve all been there: You’ve got plans, a friend says they’ll arrive in 25 minutes—and then 50 minutes later, they’re just getting in the car. The situation often snowballs into being late getting somewhere else and having to change plans or outright missing out on something.
Communication (or lack thereof) sets expectations, and you want open, honest, and punctual communication with a casting partner. When a foundry is open about its process, timelines, and any issues during production, you come to trust them and feel you can actually work with them to meet your production goals. Getting real-time updates on your production cycle can keep your customers, employees, and shareholders happy.
The way a foundry interacts with you during the quoting process can be a great test to see how they will communicate in the future.
Did they respond quickly?
Did they answer all your questions, or did they miss some things?
Did they seem personable and knowledgeable, or did it seem like they couldn't wait to get off the phone with you?
When evaluating potential partners, thoroughly assess their capabilities, QC processes, and experience. Their responsiveness and transparency should demonstrate why they deserve your business. For long-term production success, choose a foundry that operates as a true extension of your team - one that collaborates seamlessly with your operations.
3) Quality Control/Quality Assurance:
Often overlooked until there is a problem, a foundry with a solid QC and QA protocol can save your business money and a mountain of headaches throughout your partnership. When seeking out a foundry, ask about their Quality Control checks throughout the casting process. Robust QC standards help prevent production issues and catch failures long before shipping.
Quality casting partners will also have Quality Assurance systems to ensure your parts are up to snuff. Ask for material data sheets, chemistry reports, and other relevant data for your part. Before you even send a 3D model, check with them to see what systems they have in place, such as non-destructive testing or production certifications. A foundry with rigorous QA/QC standards demonstrates its commitment to quality - an investment that pays dividends throughout your production partnership.
A foundry worker monitoring temperature before metal pouring
4) Lead Times:
While not quite as crucial as getting your casting done correctly, getting your project delivered on time is still hugely important. When seeking out a foundry, ask about its lead times and ensure they align with your production goals. Asking about lead times is a great way to test how a prospective foundry communicates - are they wishy-washy, or straightforward? Lead times are multifaceted, but a quality partner can work through each piece of nuance with you to get a clear production picture.
Ask them about their current turnaround times and existing project pool to ensure you can start production on time. If your production needs change, find a foundry that can scale with you!
5) Experience & Expertise:
Earlier, we related finding a foundry to hiring a candidate. Think of a work experience on a resume like a foundry’s casting projects. Project experience and associated expertise are where the rubber meets the road for a stainless steel foundry.
A few questions to ask early in your search are:
How long have they been in business?
Have they done similar projects?
Have they worked with this alloy before?
Do they have rich experience in your industry?
Are they considerably cheaper or more expensive than other foundries you have explored? If one quote is significantly cheaper than others, it may be a sign of a dip in quality.
When evaluating expertise, there is a lot to unpack, but here are a few places to start:
Their Metallurgical Process
Before launching a project, they should understand your chosen alloy inside and out. They should know its behaviors, characteristics, and properties. If your chosen material isn't the best fit for your intended application, they should point you to a material that is a better fit. They should also be able to diagnose issues and prevent failures. Among many other things, the foundry should implement a QC plan to ensure consistent pouring results that minimize or eliminate imperfections and contaminants in the final product.
Are they busy?
Think of a foundry as a restaurant; is it easy to get a table at any time, or do you need a reservation most nights? A foundry consistently engaged in projects is adaptable, likely up to date on best practices, and very frequently well-versed in multiple industries.
How long have they been in business?
Experience comes from tackling projects large and small over years and years. Do they have reviews or a showcase of projects and companies that they have worked for?
Evaluate QA/QC Practices:
This is so important that it warrants repeating. A foundry with robust QA/QC standards is likely to be a good candidate for your project.
Communication:
Communication is also repeated here. Are they motivated about your project and bring ideas and solutions to the table? Someone who is engaged with your project will show it, and they'll be able to communicate their expertise with the material, your industry, or anything else relevant to the project at hand.
6) Certifications:
Depending on your industry, certain certifications (such as ITAR) may be required when selecting a partner foundry. Even if no specific certifications are mandatory for your project, choosing a foundry with credentials like ISO 9001 demonstrates a commitment to rigorous production methods, quality control systems, and adherence to industry standards.
Just as a D-minus health code rating should give you pause before going into a restaurant, Quality Certifications should be a green light that a foundry has quality manufacturing methods and is presumably a good partner to work with.
7) Proximity:
A foundry may tick a lot of boxes, but something to consider is its proximity to you.
Are you able to easily visit to check on production?
Is it far enough away that shipping logistics become tricky?
Is it proximal to other suppliers?
Is it in a foreign nation where supply chain concerns or tariffs may impact your bottom line?
Choosing an accessible foundry can provide a lot of benefits to your turnaround times and overall production flow.
8) Ongoing Investment:
One final key thing to look for in a long-term precision casting partner, is an ongoing investment in their facility and team. From adding new equipment and introducing new technologies to investing in team members, a foundry that invests in the future is a partner built to work with you for years to come. As an example, at IPC in 2024, we added new robotics and a new dip room to our Texas Facility, new flashfire dewaxing systems in our Utah foundry, and many other facility improvements to increase our capacity.
When a foundry invests in its team members, they stay longer and bring new skills and best practices to the table. When seeking out a stainless steel casting partner, look for one that is continually investing in its facilities and team; they are likely to be a partner you can depend on and grow with.
Wrapping Up:
Searching for a casting partner can be a bit daunting, but taking your time in selecting a quality partner can save you time, money, and production frustrations. Focusing on quality communication, level of experience, QC/QA systems, and foundries that invest in their equipment and staff will have you headed in the right direction!
At IPC Foundry Group, we work tirelessly to be a precision casting partner that you can count on. In 2024, we poured over 2,000,000 lbs of metal components for our more than 350 concurrent customers in the United States, Canada, and around the globe. With a richly experienced team, two domestic foundries, and more than 100 alloys to choose from, you can count on us to tackle your next investment casting project. Contact Us today!
