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Advanced, Large-Scale Casting

Discuss Your Casting Requirements >>
PRECISION STARTS HERE

A Skilled Workforce

The Bay Cast Companies have over 100 trained specialists committed to producing a high quality product in a timely manner.

We staff seven fulltime engineers covering areas of metallurgy, mechanical, electrical and metrology.

We employ and train skilled melt personnel, programmers, molders and welders ready to put their craft to work for you.

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Foundry Capabilities

 

BUILT FOR COMPLEX CASTINGS

Foundry Capabilities

Our casting experience includes gas turbine blade rings, pump and valve bodies, stainless steel impellers, bridge and hydroelectric components, and heavy-duty marine castings. Projects have included a 9,400-pound anchor crown for the U.S. Navy, demonstrating our ability to manufacture large, specialized steel components for demanding applications.

Bay Cast produces no-bake sand molds using a cope and drag flask or a pit mold core assembly method. We melt steel using six coreless induction furnaces and a large EAF furnace allowing us to serve our customers with a wide range of steel chemistries and casting sizes:

  • Carbon and alloy steel: 500-70,000 lbs. net cast weight
  • Tool and stainless steels: 500-27,000 lbs. net cast weight
  • Coreless Induction Melting: (4) 3.2 ton capacity — Ajax (2) 5.5 ton capacity — Inductotherm
  • EAF Melting (Acid): (1) 25 ton capacity — Swindel
  • Chemistry Lab LECO C200 carbon determinator SpectromaxX spectrometer
  • Sand System No-bake ester phenolic 48 GFN 4 sieve silica sand Chromite facing sand 1,000 lbs./min continuous mixer
  • Gating, Risers & Ladles 100% ceramic gating Insulated and exothermic risers Bottom pour, geared ladles

Melt Capacity

Six coreless induction furnaces One 25-ton acid EAF furnace

500 – 70,000 lbs

Carbon and alloy steel — net cast weight

500 – 27,000 lbs

Tool and stainless steels — net cast weight

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SOME OF OUR

Valued Clients

We love collaborating with our valued clients to solve their complex baseplate needs.
BEYOND CAST IRON

Markets Served

Space (1)
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Space market
Space market

Supporting the space industry with large-scale castings and precision-machined components engineered for demanding applications where quality, accuracy, and reliability are critical.

Defense
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Defense
Defense
Bay Cast provides heavy-section castings and precision machining capabilities for demanding defense applications, supporting projects with exacting material, dimensional, and quality requirements.
Infrastructure - Industial
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Infrastructure
Infrastructure

From major equipment to critical structural applications, Bay Cast supports infrastructure projects with large-scale casting and machining capabilities built around strength, durability, and long-term performance. 

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Civil engineering
Civil engineering
Bay Cast serves civil engineering applications with heavy-duty cast and machined components designed to meet the requirements of large-scale construction and infrastructure projects. 
Power Gen - Energy 1
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Energy
Energy
Supporting power generation and other energy applications, Bay Cast provides large castings, precision machining, and manufacturing expertise for components operating in demanding environments.
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General industrial
General industrial
Bay Cast serves a broad range of industrial manufacturers with flexible casting and machining capabilities for large, complex, and highly engineered components. 
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Mining & construction
Mining & construction
For equipment that works in demanding environments, Bay Cast produces heavy-duty cast and machined components engineered to support the strength, durability, and reliability these industries require. 
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Pumps & valves
Pumps & valves

Bay Cast supports pump and valve manufacturers with large steel castings and precision machining for components requiring dependable material performance and dimensional accuracy. 

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Gas turbine
Gas turbine
Bay Cast provides casting and large-format machining capabilities for gas turbine components, supporting the precision, material integrity, and quality requirements of power-generation applications.
Industrial plant at night
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Coal power
Coal power
For coal-fired power generation applications, Bay Cast provides heavy-section castings and precision machining for large components designed to perform in demanding operating environments. 
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CERTIFIED FOR CONFIDENCE

Manufacturing Specifications

Our company has in-depth knowledge of the many common manufacturing specifications as well as working within customer specific, proprietary requirements:
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Modeling, Simulation and ERP Software

Bay Cast employs engineering and management software throughout our wide range of processes. Our up-to-date programs are used to create, simulate and control our systems and product: Solid, Works, ESI QuikCAST, Verisurf, Master Cam, Shoptech E2, and Microsoft Dynamics.

stamping

Foundry Tooling

Our wood and polystyrene pattern tooling is CNC-machined directly from CAD data, combining modern technology with decades of foundry expertise to ensure exceptional quality from the start. With more than 40 years of experience producing large, single-use polystyrene tooling, Bay Cast delivers ideal solutions for prototypes, replacement parts, and accelerated production. Our innovative approach helps customers reduce lead times and lower costs without compromising quality.

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Quality Assurance

Bay Cast operates within an ISO 9001-based quality management system, using documented procedures, work instructions, calibration schedules, and rigorous document control to ensure consistent quality and repeatable results. We have extensive experience meeting the requirements of leading certification organizations, including ABS, DNV, and BV, and regularly host their inspectors at our facility. As an official ABS-approved steel foundry, Bay Cast delivers castings that meet the industry's highest standards. Bay Cast Foundry is an ABS-certified and approved specialty steel foundry, with ASNT-qualified nondestructive testing inspectors on staff and DDTC registration under ITAR.

CONSISTENT RESULTS, EVERY TIME

Heat Treatment and Quench Equipment

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Car Bottom Furnace (Large)

  • 15’ wide x 35’ long x 12’ high
  • Honeywell controls
  • Furnace thermocouples
  • Direct part thermocouple capable
  • Temperatures up to 1,950 F
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Car Bottom Furnace (Second)

  • 10' wide × 26' long × 9' high
  • Honeywell controls
  • Furnace thermocouples
  • Direct-part thermocouple capable
  • Temperatures up to 1,950°F
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Water Quench
Facility

  • 16' wide × 40' long × 8' high
  • 34,000-gallon capacity
  • Additional 18,000 gallons circulating
QUALITY YOU CAN MEASURE

Casting Inspection

Bay Cast has extensive in-house inspection equipment. Our ASNT inspectors perform ultrasound, magnetic particle (wet, dry, prod or yoke), fluorescent MT, Radiographic (contracted), PT and visual inspections. RT is available through contracted sources.

imensional verification is done through the use of a Faro laser tracking system as well as a large inventory of conventional layout equipment.

use our modeling software to integrate scan data from the premachine layout to our CNC machining centers. The simplified set-up and programing saves time and minimizes human error on complex geometries.

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NEW CAPABILITY

Foundry Systems and Equipment

Our advanced foundry systems and equipment enable us to produce high-quality steel castings with a wide range of chemistries and weights up to 70,000 lbs. 

Coreless Induction Melting

  • (4) Ajax — 3.2-ton capacity
  • (2) Inductotherm — 5.5-ton capacity

EAF Melting (Acid)

  • (1) Swindel — 25-ton capacity

Chemistry Lab

  • LECO C200 carbon determinator
  • SpectromaxX spectrometer

Sand System

  • No-bake, ester phenolic
  • 48 GFN, 4-sieve silica sand
  • Chromite facing sand
  • 1,000 lbs./min continuous mixer

Gating, Risers & Ladles

  • 100% ceramic gating
  • Insulated and exothermic risers
  • Bottom-pour, geared ladles

Melt Capacity

  • Six coreless induction furnaces
  • One 25-ton acid EAF furnace