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Machining

Bay Cast is a specialty job shop steel manufacturer and large format machine company serving a diverse base of industries

Engineered for Innovation

Space Market

As the space industry continues to push the boundaries of what's possible, manufacturers need partners capable of delivering precision at every stage. Bay Cast provides high-quality steel castings, advanced machining, and metrology solutions that support the production of critical components for launch systems, aerospace infrastructure, and space manufacturing. Backed by decades of expertise and integrated capabilities, we help turn ambitious designs into dependable reality. Bay Cast's aerospace machining experience includes mandrels, ship caps, tank caps, flight hardware tooling, and large precision-machined rings for launch vehicle applications. Parts machined by Bay Cast were used on a 2024 Starship test launch, demonstrating the company's involvement in advanced space manufacturing.

16,750 mm X Travel — Ingersoll Master Head 5-Axis
5,791 mm Swing Diameter — Farrel CNC Dual Ram
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Built for Mission Success

Defense

Defense manufacturers require dependable partners capable of delivering precision, durability, and consistent quality. Bay Cast produces heavy-section steel castings, large-format precision machining, and metrology solutions for mission-critical defense applications, supporting everything from ground systems and naval equipment to specialized industrial infrastructure. With integrated manufacturing capabilities and rigorous quality standards, we help ensure every component is built to perform when reliability matters most. Bay Cast also manufactures and machines specialized components for military applications, including base plates used in vehicle testing and development, naval components, and parts supporting Army programs. These projects require the large-format machining capabilities and precision measurement expertise available at Bay Cast Technologies.

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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.
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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. 
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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.
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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:
MACHINING EQUIPMENT

Large-Format Machining Equipment

Gantry Milling

Machine Axes / Control X Travel Y Travel Z Travel
REKO MEDVE 3500 3-Axis / Heidenhain 3,500 mm 2,565 mm 2,363 mm
REKO MEDVE 11400 5-Axis / Fanuc 11,400 mm 4,250 mm 1,943 mm
Ingersoll Master Head 5-Axis / Fanuc 16,750 mm 5,791 mm 4,267 mm
REKO MEDVE 6200 3-Axis / Fanuc 6,200 mm 4,250 mm 1,943 mm

Turning

Machine Control Table Diameter Swing Diameter Height Under Rail Ram Travel
Farrel CNC Dual Ram Siemens 840D 4,877 mm 5,791 mm 3,657 mm 3,050 mm
Farrel CNC Dual Ram Fanuc 4,877 mm 5,791 mm 2,438 mm 1,423 mm

Heavy Milling

Machine Axes / Control X Travel Y Travel Z Travel Heads
Ingersoll Planer Mill 3-Axis / Manual 500 in. 128 in. 72 in. (1) 150 HP horizontal
(2) 150 HP vertical

Horizontal Boring

Machine Axes / Control X Travel Y Travel Z - Ram Travel W — Spindle Travel Rotary Table Table Infeed
Union PC150 3-Axis / Heidenhain 8,000 mm 4,000 mm 800 mm 750 mm 2,400 × 3,000 mm 3,000 mm

Vertical Milling Center

Machine Axes / Control X Travel Y Travel Z Travel
Hyundai F-9608 3-Axis / Fanuc 2,488 mm 960 mm 848 mm

Inspection / Manufacturing Support

Equipment / Software
API Laser Trackers
Faro Arm 3000 mm
Ver-Surf Inspection Software
SolidWorks CAD Software
MasterCam CAM Software
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Design It Right from the Start

From early prototyping to application engineering, Bay Cast partners with customers to optimize every project before production begins. Our team provides design-for-manufacturability guidance, helping refine components for improved machinability, performance, and production efficiency while reducing potential manufacturing challenges.

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A True Extension of Your Team

At Bay Cast, every customer receives dedicated, hands-on support throughout the design and manufacturing process. Unlike larger suppliers where projects can become just another number, we build close working relationships, collaborating directly with your team to develop practical, cost-effective solutions that meet your unique requirements.

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Built for Large, Complex Components

Bay Cast specializes in producing heavy-section steel castings and precision-machined components for demanding industrial applications. Our capabilities are ideally suited for large-scale projects, with typical castings measuring up to 10 feet by 10 feet and weighing 25,000 to 40,000 pounds. When your project requires exceptional size, strength, and precision, our integrated manufacturing capabilities are built to deliver.

CONSISTENT RESULTS, EVERY TIME

Heat Treatment and Quench Equipment

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Car Bottom Furnace:
Car Bottom Furnace:
  • 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:
Car Bottom Furnace:
  • 10’ wide x 26’ long x 9’ high
  • Honeywell controls
  • Furnace thermocouples
  • Direct part thermocouple capable
  • Temperatures up to 1,950 F
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Water Quench Facility:
Water Quench Facility:
  • 16’ wide x 40’ long x 8’ high
  • 34,000 gallon capacity
  • Additional 18,000 gallon 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, 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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