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Creating a Safer, Quieter, and Cleaner Work Environment

Waupaca Foundry’s Plant 1 engineering and maintenance teams achieved a major milestone in worker safety and environmental health. In just under two weeks in 2024, the team completed a capital project at its gray iron foundry located on Division Street in Waupaca, Wis. A decades-old vibratory conveyor system was replaced with an upgraded, ergonomically designed solution that is already transforming daily life for operators sorting iron castings to blast equipment for cleaning and finishing to become finished parts.

Megan Mulholland | Waupaca Foundry

#iron-casting #safety

Waupaca Foundry

Iron Castings - May 16, 2025

Accelerate Your Iron Casting Launch With Waupaca Foundry

Waupaca Foundry offers five in-house rapid prototyping solutions, a capability few foundries in North America match. In-house rapid prototyping, reduces complexity and delays from third-party vendors enables tighter communication, better process control, and improved lead times. Waupaca’s prototyping uses the same processes and materials as full-scale production and results in consistent, reliable iron casting quality—ideal for functional testing or limited production.

Megan Mulholland | Waupaca Foundry

#additive #iron-casting #technology

Waupaca Foundry

Iron Castings - Nov 11, 2024

Gray Iron: The Ideal Material for Automotive & Commercial Truck Brakes

Gray cast iron has long stood as the cornerstone of brake systems in automotive and commercial truck applications. Its multifaceted properties make it the go-to material capable of meeting the arduous demands of braking operations.

Andrew Halonen | Mayflower Consulting

#iron-casting

Waupaca Foundry

Iron Castings - Oct 9, 2024

Waupaca Foundry earns GM award

Waupaca Foundry Plant 4 ductile iron foundry in Marinette, Wisconsin was recognized with the 2023 General Motors Supplier Quality Excellence Award (SQEA).

Modern Casting

#award #iron-casting

Waupaca Foundry

Iron Castings - Jul 29, 2024

The evolution of off-highway drivetrains

Jeroen Decleer, senior vice president Off-Highway Drive and Motion Systems at Dana Inc., said the off-highway market has changed a lot and there has been a push to a great extent to move to electric vehicles. Jeroen Decleer, senior VP Off-Highway Drive and Motion Systems, Dana Now, this is nothing truly unexpected and a trend that all OEMs and component manufacturers in the off-highway space are experiencing. It is important to note, though, how this changed scenario has affected manufacturers of traditional drivetrain components, such as Dana, that have morphed into full system suppliers for the whole powertrain, including components that power and operate the machines. Decleer confirmed that the trend to electrification is certainly a focus for his company, but it is not the only one.

Roberta Prandi | Power Progress

#EV #iron-casting #off-highway

Waupaca Foundry

Iron Castings - May 1, 2024

Metalcasting Congress 2024: Celebrating Success and New Leadership

The American Foundry Society is pleased to announce the success of Metalcasting Congress 2024, held at Milwaukee's Baird Center on April 23–25, 2024.

American Foundrymen's Society

#afs #award #manufacturing

Waupaca Foundry

Iron Castings - Apr 24, 2024

In a seminal development for Wisconsin's economy, manufacturing has begun returning home

Manufacturers say one of their biggest worries is that a shortage of skilled workers threatens to undermine growth.

Rick Barrett | Milwaukee-Journal Sentinel

#iron-casting

Waupaca Foundry

Iron Castings - Apr 12, 2024

Dimensional Tolerance Assessment of Iron Castings Production Using 3D Printed Sand Process | Modern Casting

Foundries have adopted various additive manufacturing (AM) processes over the years––in particular, 3D printed sand using the binder jet process to make cores and molds has been embraced by over 90% of the foundries per recent surveys. The use of 3D printed sand casting is growing in the production environment, and the initial feedback is that the process results are comparable to the precise sand-casting processes. Currently, 3D sand printing is predominantly used in production via a hybrid approach, where the mold is made using the conventional green sand process and the complex core assembly is redesigned with a consolidated 3D-printed core. However, little has been studied and is known in the public domain about the dimensional tolerances achieved with this toolingless precision sand casting process, especially the potential of achieving truer position and better internal feature tolerances.

Jiten Shah | Modern Casting

#3dprinting #casting #iron-casting

Waupaca Foundry

Iron Castings - Feb 26, 2024

Gate and Spure Conveyor Improves Plant 4 Uptime, Workplace

The task was clear: the Plant 4 engineering and maintenance teams were to upgrade the shaker system that transports ductile iron casting gates and sprues in two weeks over the 2023 holiday shutdown. In-house engineering and maintenance teams began planning for the capital project in 2022 with the objective of tackling all the identified challenges associated with equipment, including material congestion, noise, dust generation, downtime, and rising costs.

Mary Schmidt | Waupaca Foundry

#capex #iron-casting #marinette

Waupaca Foundry

Iron Castings - Jan 15, 2024

What U.S. Metalcasters Need to Know About New Regulations Going into 2024 | Modern Casting

Heading into 2024, several regulations should be on the radar of U.S. metalcasters. U.S. Department of Labor (DOL) Overtime Rule. The DOL has proposed increasing the overtime exemption threshold regulations applicable to executive, administrative, and professional employees. The current threshold is $35,568 annually, and under this proposed rule, employees making less than $1,059 per week or $55,068 annually would be eligible for overtime pay. It will also increase the earnings thresholds every three years automatically.

Stephanie Salmon | Modern Casting

#jobs #manufacturing #metalcasters

Waupaca Foundry

Iron Castings - Dec 8, 2023

Printing Payback

Thanks to investment in an ExOne S-MAX Pro 3D sand printer, Waupaca Foundry is now able to turn around a prototype in days instead of weeks. It’s a long list of potential use cases, many of which were probably never anticipated when she fired off the purchase order for that machine. And so it is with desktop printers’ more productive and accurate counterparts: production 3D printers. Here, end-use parts in polymer and metal alike are possible.

Kip Hanson | Smart Manufacturing

#3dprinting #sustainability

Waupaca Foundry

Iron Castings - Sep 29, 2023

Getting to the Core of Additive Manufacturing

The rise of automated intelligence has transformed the manufacturing landscape.

Kim Viduski | Waupaca Foundry

#3dprinting #iron-casting #manufacturing

Waupaca Foundry

Iron Castings - Apr 26, 2023

Waupaca Foundry Adopts Horizontal Molding

The ferrous foundry group – long known for green-sand vertical molding – has added a Sinto America molding line and ExOne sand printer for cores, in response to customer demand.

Foundry Management & Technology

#iron-casting #waupaca

Waupaca Foundry

Iron Castings - Apr 24, 2023

Expanding the foundry's production capabilities

Waupaca Foundry hosts ‘first-pour’ event signaling the official opening of its new horizontal molding production line

The Business News

#businessnews #production

Waupaca Foundry

Iron Castings - Mar 23, 2023

Waupaca Foundry Reprises Horizontal Molding For a Great Fit

It has been over 30 years since Waupaca Foundry has had horizontal molding capabilities. In May of 1967, Waupaca Foundry installed its first vertical molding machine, and by the early 1990s, the last of the horizontal molding machines were removed.

Janelle Bailey | Waupaca Foundry

#iron-casting #waupaca

Waupaca Foundry

Iron Castings - Dec 16, 2022

All Hands on Deck For Critical Cupola Replacement

Proactive planning and foresight, all-in collaboration, and effective communication resulted in success for a staggering undertaking: replacing one of two cupolas at Waupaca Foundry Plant 5 in Tell City, Indiana, and within a four-week window. The entire project was executed, though truly a “Herculean effort,” according to Bruce Tesch, Director of Melt and Manufacturing Processes, essentially due to the steady and dedicated efforts of all involved.

Janelle Bailey | Waupaca Foundry

#iron-casting #tellcity #upgrade

Waupaca Foundry

Iron Castings - May 27, 2022

Companies Team Up to Create Award-Winning Casting

Two Wisconsin-based companies, Amerequip and Waupaca Foundry, recently teamed up to create a metal casting that is creating a buzz in the commercial lawn, landscape and agricultural markets.

Insight Publications

#casting #supplychain

Waupaca Foundry

Iron Castings - Apr 12, 2022

Casting of the Year: Waupaca's Collaboration on a Backhoe Bucket

Waupaca Foundry’s Plants 4 and 5 have been awarded Casting of the Year for a 12-in. bucket assembly for the backhoe of a compact utility tractor.

Shannon Wetzel | Modern Casting

#award #casting #castiron #innovation #iron-casting #marinette #reshoring #supplychain #tellcity

Waupaca Foundry

Iron Castings - Apr 5, 2022

Visit Waupaca Foundry at CastExpo '22

Hundreds of exhibitors and thousands of attendees will converge at the Greater Columbus Convention Center on April 23-26 for CastExpo hosted by American Foundry Society & Metalcasting Congress. Waupaca Foundry, the industry's leading iron casting supplier, is proud to be an exhibitor, booth #2641.

Waupaca Foundry

#events #iron-casting

Waupaca Foundry

Iron Castings - Mar 2, 2022

INFOGRAPHIC: Bonanza for Brazilian pig iron pricing, trade | S&P Global Commodity Insights

Brazilian merchant pig iron prices escalated by more than $300/mt since the beginning of the coronavirus pandemic, while export volumes surpassed 10 year highs on the back of emerging Chinese demand and elevated iron ore prices.

S&P Global

#iron-casting #trade

Waupaca Foundry

Iron Castings - Feb 7, 2022

U.S. and Japan Reach an Agreement to Remove Trump-Era Steel Tariffs

The U.S. and Japan reached a truce that will allow most steel shipments from the Asian nation to enter tariff-free for the first time since 2018 and sees the countries working together to combat Chinese trade practices that harm the industry. Washington will suspend the 25% levy on incoming steel imports from Japan up to 1.25 million metric tons a year, officials from the Commerce Department and U.S. Trade Representative's office told reporters on Monday.

Eric Martin, Jenny Leonard, and Isabel Reynolds | Bloomberg

#steel #tariff #trade

Waupaca Foundry

Iron Castings - Dec 10, 2021

The 74th World Foundry Congress

In October 2022, Busan in Korea will be the venue of the 74th World Foundry Conference. The event has been postponed to 2022 for corona reasons and should be able to take place without any problems according to the current situation. Let's hope that everything works out on the way there. Make a note of the date and the keynote lectures, submit your own lectures and start thinking now about how you can enrich the international foundry family and contribute your impulses.

Foundry-planet.com

#castiron #events

Waupaca Foundry

Iron Castings - Nov 19, 2021

Light Minded

As automotive makes a slow transition from internal-combustion-engine vehicles (ICEVs) to electric vehicles (EVs), the evolution will find foundries morphing and honing their expertise to meet the changing demands of OEMs, or, in some cases, diversifying their businesses toward other sectors in the long term. But for the next two or three decades to come, castings in ICEVs are not only safe from extinction, they'll continue getting lighter and performing better.

Kim Phelan | Modern Casting

#automotive #casting #manufacturing

Waupaca Foundry

Iron Castings - Nov 16, 2021

Underground Hero

Machining was, in fact, the lynchpin that ultimately enabled multiple Slimcast SKUs to be derived from a single casting, as opposed to producing multiple castings, each with separate tooling.

Kim Phelan | Casting Source

#innovation #waupaca #wf #wfnews

Waupaca Foundry

Iron Castings - Nov 16, 2021

THROUGH THE EYES OF A METALCASTER

When you are in the casting design process, you go to great lengths to make sure the resulting casting meets your needs. You spend time making sure the material selection meets your strength and durability criteria, you make sure the shape of the casting meets your load constraints, and the dimensions satisfy all your assembly and fit requirements. Your final design meets all your needs when viewed through the eyes of your manufacturing and engineering teams. So, you send out the casting design to your foundry source for a production quote. Now comes the time when your design is evaluated through a different set of eyes — the eyes of the foundry team. But did you ever wonder what your casting design looks like to the foundry? What do their manufacturing and quality teams look for? I'll give you a hint, it's a lot more than you might think.

Dave Charbauski | American Foundry Society

#iron-casting #manufacturing #materials

Waupaca Foundry

Iron Castings - Jul 12, 2021

Outstanding Achievement

Waupaca Foundry earns AFS Casting Competition Outstanding Achievement for the design and production of Oil Tool Solutions' Slimcast Hulk clamp.

Modern Casting

#afs #award #iron-casting #wfnews

Waupaca Foundry

Iron Castings - Jun 1, 2021

Waupaca Foundry Replaces Wheels on Stand Grinders

The health and safety management system at Waupaca Foundry relies in part on risk reduction featuring continual improvement initiatives designed to progress manufacturing processes and improve safety. In this same spirit, Waupaca Foundry’s Plant 6 ductile iron plant located in Etowah Tennessee, saw an opportunity to reduce risk in its mill room. Stand grinding equipment in the mill room is used to grind, clean, and finish ductile iron castings. The wheels on the stand grinding equipment posed risk, however. The plant aimed to replace the traditional bonded abrasive wheels with diamond-plated wheels on its large 20 HP stand grinders to improve operator safety, improve maintenance.

Hanna Henrich-Waller | Waupaca Foundry

#etowah #millroom #safety

Waupaca Foundry

Iron Castings - Feb 17, 2021

Waupaca Foundry keeps its attention on customer support, employee safety

Proving their mettle: Good suppliers stay the course during challenging times in the same way certain friends can be counted on when the going gets tough. Good suppliers stay the course during challenging times in the same way certain friends can be counted on when the going gets tough. There have been a lot of mettle-testing opportunities at every step in the supply chain over the past year.

Chad Elmore | Diesel Progress

#iron-casting #safety #supplychain

Waupaca Foundry

Iron Castings - Sep 28, 2020

Advancing 3D Printing for Metalcasting

The number of companies both producing printed sand molds and cores and the companies using the technology has quadrupled in the last three years.

J. Thiel, N. Bryant, K. Woods, Eerson Process Management | Casting Source

#3dprinting #iron-casting

Waupaca Foundry

Iron Castings - Sep 28, 2020

Looking at Castings Environmental Impact Across Their Life Cycles

The transport sector is responsible for approximately 23% of global energy-related CO2 emissions and is expected to increase at a faster rate than other energy end-use sectors.

Jeremy Lipshaw | Casting Source

#iron-casting #recycle

Waupaca Foundry

Iron Castings - Sep 16, 2020

Achieving Better Sand-Temperature Control at Waupaca Foundry | Solex Thermal Science

In foundry operations, consistent sand-temperature control during coremaking is essential to maintaining process costs, product bench life, and overall quality. Yet that temperature consistency also can be the most difficult to achieve.

Jamie Zachary | Foundrymag

#materials

Waupaca Foundry

Iron Castings - Jun 12, 2020

Foundry Sand Conditioning Case Study

The Solex heat exchanger proves to be a great value-added system. According to Waupaca Foundry Assistant Production Manager – Coremaking, Adam Kurszewski, the systems required zero maintenance. Foundries may also realize quality improvements and cost reductions through reduced core scrap and rework of cores. Casting scrap and salvage have also been reduced through the optimized use of binders.

Adam Kurszewski | Waupaca Foundry

#foundrysand #materials

Waupaca Foundry

Iron Castings - Jun 11, 2020

Best Casting Conversion Award

See how Bad Boy Mowers improved quality and durability by replacing an 8-piece steel weldment with a 1-piece iron casting resulting in an AFS Award.

Mackenzie Morey | Waupaca Foundry

#award #iron-casting

Waupaca Foundry

Iron Castings - Jun 4, 2020

Trends in Lightweighting with Metal Castings

The best applications in lightweighting cut costs while improving performance. Waupaca Foundry achieved success on an automotive steering knuckle, converting an aluminum forging to an optimized ductile iron design that is 20% stronger, 25% stiffer and 40% lower cost, while narrowing the weight delta to an acceptable 1.32-kg increase over the forging.

Andrew Halonen | Casting Source May/June 2020

#iron-casting #lightweighting #wfnews

Waupaca Foundry

Iron Castings - Jan 5, 2020

National Technology Day

Three ways Waupaca Foundry utilizes ever-changing technology to better business operations

Ally Melby | Waupaca Foundry

#3dprinting #energy #robotics

Waupaca Foundry

Iron Castings - Sep 9, 2019

3-ways vehicles are reducing weight

Lightweighting vehicles is not a new concept—the Corporate Average Fuel Economy (CAFE) standards were passed in 1975—but automotive manufacturers continue to find ways to trim the pounds. See real case studies.

MCDP Staff Report | Metal Casting Design

#automotive #lightweighting #supplier

Waupaca Foundry

Iron Castings - Jun 17, 2019

Foundry of the Week: Waupaca Foundry

Waupaca Foundry, a Hitachi Metals Group company, has a reputation as solid as the castings we create. We deliver on our daily commitment to quality and true capacity.

foundry-planet.com

#castiron #innovation #iron-casting #lightweighting

Waupaca Foundry

Iron Castings - May 23, 2019

Waupaca Foundry at NEWCAST in Germany

NEWCAST, hosted by Messe is among the largest trade fairs for precision castings is held in Dusseldorf, Germany. Waupaca Foundry is proud to be an exhibitor in Hall 14 at booth D36.

Ally Melby | Waupaca Foundry

#events

Waupaca Foundry

Iron Castings - May 16, 2019

Lightweighting achieved through Design Optimization and High-Strength Ductile Iron

Rising fuel efficiency and emissions standards are driving an increased demand for lightweight automotive components. While aluminum materials are commonly specified, Waupaca Foundry in collaboration with Hitachi Metals America have the capabilities through design optimization and high-strength ductile iron to meet weight reduction goals while generating significant cost savings and a stronger component.

Waupaca Foundry

#lightweighting

Waupaca Foundry

Iron Castings - Apr 28, 2019

Waupaca Foundry Opens Machine Shop for Brake Parts

Waupaca Foundry Inc. is opening a machining operation adjacent to one of the three gray iron foundries it operates in Waupaca, WI. The new plant will machine commercial-vehicle brake components cast at the foundry, an expansion resulting from customer demand.

FMT Staff | Foundrymag

#expansion #waupaca

Waupaca Foundry

Iron Castings - Apr 24, 2019

Waupaca Foundry opens machining facility

Waupaca Foundry, a Hitachi Metals company, announced the opening of the company's first machining facility in Waupaca. The company opened the Waupaca Foundry Machine Center in the old Buyers Guide building at 600 Industrial Drive in Waupaca. It operates another machining center in Effingham, Ill. The center will turn finished castings into finished parts. The machining process adjusts cast parts to meet the tight tolerances from customers, in some cases adjusting a part to less than one-thousandth of an inch — smaller than a human hair.

Jessica Thiel | Insight Publications

#machining #waupaca #wfnews

Waupaca Foundry

Iron Castings - Mar 25, 2019

Waupaca Foundry announces alliances

Waupaca Foundry, Inc., a Hitachi Metals company based in Waupaca, Wis., has entered into separate manufacturing alliances with Dotson Iron Castings and Kohler Industrial Castings. Under the agreements, Waupaca Foundry customers requesting horizontal molding will access Kohler's and Dotson's capabilities with a streamlined supply chain managed by Waupaca Foundry. Waupaca Foundry operates 35 vertical molding machines nationwide. Both Dotson and Kohler recently installed new horizontal molding capacity. Offering both horizontal and vertical molding capabilities provides casting buyers the flexibility to source suppliers to best suit their production needs.

Chad Elmore | Diesel Progress

#iron-casting

Waupaca Foundry

Iron Castings - Mar 5, 2019

Visit Waupaca Foundry at CastExpo '19

Hundreds of exhibitors and thousands of attendees will converge at the Georgia World Congress Center on April 27-30 for CastExpo hosted by American Foundry Society & Metalcasting Congress. Waupaca Foundry, the industry's leading iron casting supplier, is proud to be an exhibitor, booth #431.

Waupaca Foundry

#events #iron-casting

Waupaca Foundry

Iron Castings - Feb 19, 2019

Nine Green Sand Facts to Know

The green sand casting process is the most widely-used process for casting ferrous and nonferrous metals. The process has evolved from a manually intensive operation to a highly mechanized and fully automated process that can produce more than 300 molds per hour. When sourcing a casting supplier, there are several facts to remember about green sand.

MCDP Staff | Casting Source

#iron-casting

Waupaca Foundry

Iron Castings - Feb 12, 2019

Trusted Iron Casting Component Supplier for Trailer

Waupaca is a trusted supplier of Class 8 commercial vehicle trailer components. You will find Waupaca Foundry iron castings, machined and assembled, on flatb...

WaupacaFoundry | YouTube

#castiron #iron-casting

Waupaca Foundry

Iron Castings - Dec 6, 2018

Trusted Iron Casting Supplier for Material Handling Equipment

Waupaca is a trusted supplier of material handling equipment. You will find Waupaca Foundry iron castings on forklifts, pallet jacks, reach trucks, order pic...

Waupaca Foundry

#off-highway

Waupaca Foundry

Iron Castings - Jun 25, 2018

Waupaca Foundry Gets Toyota Award

Waupaca Foundry said it has earned one of the five available professional excellence awards from Toyota Industrial Equipment Manufacturing (TIEM), which builds forklifts in Indiana. The foundry said it is the first Tier 2 supplier to be recognized with the award. The foundry has supplied iron castings to TIEM since 2002 including hubs, drums, brackets, wheels and sheaves. In 2017, it received a contract to produce 21 parts at its gray and ductile iron foundries in Waupaca and Marinette, Wis., and Tell City, Ind.

Chad Elmore | Diesel Progress

#marinette #tellcity #waupaca #wfnews

Waupaca Foundry

Iron Castings - Jun 20, 2018

METALCASTER OF THE YEAR: Sustainability Drives Waupaca Foundry

Waupaca Foundry earned 2018 Metalcaster of the Year in recognition for our commitment to sustainability.

Shannon Wetzel | Modern Casting

#award #greenaward #iron-casting #wfnews

Waupaca Foundry

Iron Castings - Mar 12, 2018

Waupaca Foundry says supply chain fuels growth

Waupaca Foundry has put the Great Recession well into its rear view mirror as the plant here that makes iron castings for parts used in cars and trucks now employs a five-year high of 560 people. One company advantage executives cite is the use of a just-in-time supply chain that they say is unique in their industry and a cost-saver for the business.

Mike Pare | timesfreepress.com

#supplier #wfnews

Waupaca Foundry

Iron Castings - Nov 21, 2017

Lightweighting Through Redesign Furthers Fuel Economy Goals

An automotive OEM diligently working to meet government-mandated fuel economy goals sought Waupaca Foundry to achieve its lightweighting objectives. The targeted component is a differential carrier in the powertrain on the company's light duty trucks already in production.

#automotive #lightweighting #powertrain #tellcity

Waupaca Foundry

Iron Castings - Nov 7, 2017

Trusted Iron Casting Supplier for Oil & Gas

Waupaca is a trusted supplier for oil and gas, both on and off the oil field. From oil transport, pumps, jacks and wells, you will find Waupaca Foundry iron ca...

WaupacaFoundry | YouTube

#iron-casting #oil

Waupaca Foundry

Iron Castings - Nov 1, 2017

Waupaca Foundry Earns Ford Q1 Certification

Waupaca Foundry Plant Manager, Kenley Hansen (far left) and Quality Assurance Manager, Sylvia Chavez Tarlton (middle right) accept the Ford Q1 plaque in front on the newly-rasied Q1 flag. Also pictured are Ford Motor Company, Michelle Walker (middle left) and Ratan Ray (far right).

Sara Timm | Waupaca Foundry

#award #tellcity #wfnews

Waupaca Foundry

Iron Castings - Oct 29, 2017

Building for the Future

Foundry construction can be a difficult challenge. Whether it’s building a completely new plant or adding onto an existing facility, obstacles come up that are both expected and surprising. See how Waupaca Foundry manages.

Brian Sandalow | Modern Casting | AFS

#expansion

Waupaca Foundry

Iron Castings - Oct 3, 2017

Defining Automation's Role in 'Future' Manufacturing

Are robots simply utilities in a wider web of digital design and production? Or, tools for operators to execute their programs? The debate is on.

FMT Staff | Foundry Management & Technology

#automation

Waupaca Foundry

Iron Castings - Sep 21, 2017

Hurricanes Deliver Shock to Scrap Metal Market

After the string of ferocious hurricanes and an 8.2 magnitude earthquake in southern Mexico, the markets assume that the destruction will produce an abundance of scrap metal that it is ready for collection and recycling. These markets hope the result will be falling prices in expectation of an oversupply. The reality is quite different.

Shelley Goldberg | Bloomberg.com

#scrap

Waupaca Foundry

Iron Castings - Sep 17, 2017

Waupaca Foundry among Top 16 for 'Coolest Thing Made In Wisconsin' contest

The contest has received nominations for products made in every corner of the state. Waupaca Foundry is the nationâ€™s largest foundry and makes gray and ductile iron castings at four foundries located in Waupaca and Marinette. The iron casting supplierâ€™s products are used in automobiles, agricultural machinery, construction equipment, heavy trucks, rail, oil and gas and other industrial sectors.

Solid As The Castings We Create | Waupaca Foundry

#award #manufacturing

Waupaca Foundry

Iron Castings - Jun 27, 2017

Waupaca Foundry gains boiler recertification

Sample cast iron boiler sections produced by Waupaca Foundry

#asme #castiron #iron-casting #waupaca

Waupaca Foundry

Iron Castings - Jun 9, 2017

Air disc brakes likely to become most popular option, but drums 'will not go away'

Adoption rates for air disc brakes (ADB) have climbed more than 100 percent in the last five years. See how this is affecting the use of drums in new auto platforms.

Commercial Carrier Journal

#trucking

Waupaca Foundry

Iron Castings - May 15, 2017

Waupaca Foundry receives awards for casting, engineering

Iron casting supplier, Waupaca Foundry earned Best in Class for a ductile iron suspension casting converted from aluminum that achieved one of the Detroit Big Three's lightweighting objectives for a major automotive platform. "Our customers seek collaborative casting design and innovative materials solutions that add value to their products," says CEO Mike Nikolai. "These industry awards confirm that our teams are delivering consistent, top-tier quality and service that leads the industry."

Jessica Thiel | Insight Publications

#afs #iron-casting #lawrenceville #wfnews

Waupaca Foundry

Iron Castings - Feb 8, 2017

Driveline Differential Case Loses Weight | Waupaca Foundry

Case Study | PDF Download Lightweight ductile iron casting: Differential case casting weight reduced by 41%, machined by 60%.

Waupaca Foundry

#automotive #driveline

Waupaca Foundry

Iron Castings - Feb 8, 2017

Markets Served

At Waupaca Foundry, we move people. We build infrastructures. We cultivate opportunities. We create ductile and gray iron castings the world uses and trusts.

Waupaca Foundry | YouTube

#iron-casting #supplier

Waupaca Foundry

Iron Castings - Feb 8, 2017

Trusted Supplier of Commercial Vehicle Iron Castings

A trusted supplier to the Class 4-8 and trailer market, Waupaca Foundry produces a host of gray iron, ductile iron, austempered ductile iron (ADI), and compa...

Waupaca Foundry | YouTube

#iron-casting #supplier

Waupaca Foundry

Iron Castings - Feb 8, 2017

Trusted Supplier of Automotive Iron Castings

A trusted supplier to the passenger car and light truck transportation market, Waupaca Foundry produces a host of gray iron, ductile iron, austempered ductil...

Waupaca Foundry | YouTube

#automotive #iron-casting #supplier

Waupaca Foundry

Iron Castings - Feb 8, 2017

Trusted Iron Casting Supplier to the Rail Industry

Waupaca is a trusted supplier to the passenger and freight rail industry. From freight, coal, oil and tank cars, Waupaca Foundry castings can be found in loc...

Waupaca Foundry | YouTube

#rail #supplier

Waupaca Foundry

Iron Castings - Jan 11, 2017

Waupaca Foundry Named John Deere 'Partner' Supplier

Waupaca Foundry has earned recognition as a partner-level supplier for 2016 in the John Deere Achieving Excellence Program. The Partner-level status is Deere & Co.'s highest supplier rating. John Deere Supply Management created the program in 1991 to provide a supplier evaluation and feedback process that promotes continuous improvement.

Foundry-Planet.com

#award #off-highway #supplier #wfnews

Waupaca Foundry

Iron Castings - Jan 3, 2017

Cut the weight | Move more freight | Truck News

You may not be able to bring your semi-truck to the gym or a Zumba class to help it shed those extra pounds, but there are ways fleets can tip the scales in their favor and get their trucks to lose some weight so they can move more freight.

Derek Clouthier | Truck News

#lightweighting

Waupaca Foundry

Iron Castings - Jan 1, 2017

Ricardo-Designed Ultra-Lightweight Driveline System

A systems approach to product design for mass optimization is key to this driveline lightweighting project involving multiple industry leaders. "The Ricardo contribution to the ULTRAN project has demonstrated the very significant opportunities for driveline lightweighting that can be realized when a systems approach to product design for mass optimization, is applied by our highly experienced and creative engineers."

LightWeighting World

#driveline #lightweighting

Waupaca Foundry

Iron Castings - Sep 22, 2016

Visit Waupaca Foundry at IZB 2016 Booth 4203 Hall 4

Waupaca Foundry and Hitachi Metals will join Volkswagen, other OEM's and 750 Tier suppliers at IZB 2016 October 18 — 20. IZB 2016 is being held at the AutoBook International Pavilion located next to the global Volkswagen Headquarters in Wolfsburg, Germany. Stop by and talk to Waupaca Foundry's Carsten Behrensmeier and James Newsome at IZB 2016 Booth 4203 in Hall 4 to discuss your next project.

#automotive #events #iron-casting

Waupaca Foundry

Iron Castings - Sep 13, 2016

Visit Waupaca Foundry at the 2016 InnoTrans Technology Fair

InnoTrans, the world's leading transport technology fair, is set to attract more than 135,000 visitors from 55 countries to Berlin in September 2016. Waupaca Foundry, Inc. is on track to showcase our portfolio of gray iron and ductile iron castings for use by passenger and freight car component manufacturers. Join or follow us in Berlin as we discuss our advanced manufacturing technology, consistent high quality, and continuous cost conscience methodology with OEM's and Tier 1 Suppliers to the rail industry.

#events #rail

Waupaca Foundry

Iron Castings - Aug 8, 2016

Waupaca Foundry lightweight ductile iron knuckle increases suspension strength

The Honda Ridgeline receives a unibody revolution and its suspension components have been beefed up. Even its steering knuckle, made by Waupaca Foundry in Lawrenceville, Penn. is stronger than it's Honda Pilot counterpart, but nearly as light. The article nods to Hitachi Metals HNM Series high-strength ductile, which allows components to be lighter weight while also more durable. As a result of the redesigned knuckle, the Honda Ridgeline front and rear suspension is 17% and 31% stronger, respectively.

Car and Driver

#lawrenceville #lightweighting #wfnews

Waupaca Foundry

Iron Castings - Jul 31, 2016

Stiff Duties Expected on Driveline Components from China and Canada

The Department of Commerce and International Trade Commission suspect driveline components exported from China and Canada to the US are sold at prices below fair market value or are being subsidized by a foreign "authority". However, a new anti-dumping or countervailing duty rule could change that. Preliminary findings of investigations by the Department of Commerce into subsidies and dumping allegations indicate that duties could soon be imposed on iron castings from these two countries.

Sara Timm

#driveline #tariff

Waupaca Foundry

Iron Castings - May 5, 2016

Five Ways to Achieve Lightweighting Objectives with Iron Castings

The Corporate Average Fuel Economy (CAFE) standard is set to hit 54.5 mpg in 2025, so itâ€™s no surprise the auto industry is aggressively pursuing ways to increase fuel efficiency. The Center for Automotive Lightweightingâ€™s Web site states that the use of lightweight materials in vehicles will significantly increase fuel efficiency and cut emissions. As the market takes a serious step towards increasing fuel economy, the topic of material substitution is at the forefront. Gray and ductile iron material is not exactly perceived as lightweight. But, use of this higher-strength iron, allows for design engineers to use less material. Now weâ€™re talking.

Steven Kitzinger | Waupaca Foundry

#iron-casting #lightweighting

Waupaca Foundry

Iron Castings - Apr 19, 2016

Waupaca Foundry unveils New Strategy

Nearly two years into its relationship with Hitachi Metals?, a Japan-based company with machining and metalcasting operations in Asia and North America, Waupaca Foundry appears to be shifting into high gear. In early 2016, the company unveiled a four part series of capital investments and strategic initiatives along with longterm expansion possibilities to improve its standing in the global market.

Nick Leider | Modern Casting

#wfnews

Waupaca Foundry

Iron Castings - Apr 14, 2016

Waupaca Foundry Announces Key Strategic Initiatives For Global Growth Following Merger

On April 1, 2016 the merger of Waupaca Foundry and Hitachi Metals Automotive Components USA (HMAC) was finalized. The merger solidifies Waupaca Foundry's vision to increase revenue and profitability while maintaining diversity across markets and sectors.

#ductile #mexico

Waupaca Foundry

Iron Castings - Apr 9, 2016

Value Analysis / Value Engineering: Collaboration Drives Out Costs

Value Analysis and Value Engineering (VA/VE) is an intensive, innovative, and systematic problem-solving process used to drive cost out of our customer's iron castings and improve quality.

Michael Behring | Waupaca Foundry

#iron-casting

Waupaca Foundry

Iron Castings - Mar 2, 2016

White-hot opportunities

Hitachi Metals Foundry America, the parent company of Waupaca Foundry, announced in February a merger between the Waupaca-based company and fellow subsidiary Hitachi Metals Automotive Components USA. HMAC will become a division of Waupaca Foundry, which should emerge from realignment as a stronger player in key markets, particularly automotive. - See more at: http://www.waupacafoundry.com/en/our-company/news/waupaca-in-the-news

Sean P. Johnson | Insight on Business

#ma #supplier #wfnews

Waupaca Foundry

Iron Castings - Feb 1, 2016

Improving the Quality of Castings at Waupaca Foundry

The quest for quality castings drives Waupaca Foundry to constantly seek out improvement opportunities. To this end, the core assembly and Waupaca Way teams examine foundry processes, adhesives, jigs, designs, and whatever else it takes to establish a new—and better—best practice.

Scott Bailey | Waupaca Foundry

#iron-casting #waupaca

Waupaca Foundry

Iron Castings - Jan 31, 2016

Collaboration That's a Cut Above | Waupaca Foundry

Collaborating with a global leader in commercial turf and lawn care equipment, Waupaca Foundry worked to drive out costs from a mower bumper cast in gray iron, and thereby enhanced the zero-turn commercial mower's performance.

Mike Behring | Waupaca Foundry

#iron-casting #lightweighting

Waupaca Foundry

Iron Castings - Oct 1, 2015

Waupaca Foundry | Moving Forward

Waupaca County Post,Â October 1, 2015

Waupaca County Post

#expansion #waupaca #wfnews

Waupaca Foundry

Iron Castings - Sep 21, 2015

A Streamlined Process From Purchase Order to Tool Build and Everything In Between

For Waupaca Foundry customers, it is useful to understand how we work. Read how our collaboration and close consultation allow us to lead our customers through the iron castings process.

Waupaca Foundry

#iron-casting

Waupaca Foundry

Iron Castings - Aug 26, 2015

Iron Casting Quote Request: 5 Ways to Slow Down the Response Time

Whether you have a new project that requires foundry work or are considering a switch to a new supplier, the task of sourcing product and qualifying a supplier can be a challenging process. At Waupaca Foundry, every iron casting quote request or RFQ is rigorously reviewed to assure casting feasibility. Each RFQ is evaluated to ensure completion, verifying that all necessary information has been included before it enters the quoting process. This review also includes scanning and creation of digital files for all RFQ information and drawings. Unfortunately, a few common missteps can quickly derail the process of getting a timely and meaningful quote.

Waupaca Foundry

Iron Castings - Jul 13, 2015

Mike Nikolai Receives Sustainable Leadership Award

Molten metal filters are used in the iron casting process to prevent slag and other harmful inclusions from entering the mold and ending up in the final casting. There are several types of molten metal filters to choose from. However, to guarantee the best performance from any filter, it is critical to have an understanding of the physical characteristics of the slag or inclusions specific to your foundry application.

Halden Collins | Waupaca Foundry

#greenaward #innovation #iron-casting

Waupaca Foundry

Iron Castings - Nov 18, 2014

Waupaca Foundry Commended as Bobcat Celebrates 1 Millionth Loader

Waupaca Foundry is pleased to congratulate Bobcat Company on the production of its 1 millionth loader. We are proud and honored to be highlighted as a preferred partner by Bobcat in recognition of this achievement that was over 50 years in the making.

Patrick Neitzel | Waupaca Foundry

#iron-casting #off-highway #supplier

Waupaca Foundry

Iron Castings - May 4, 2014

Ductile and Gray Iron Foundry | Supplier of the Year | Waupaca Foundry

Waupaca Foundry's Plant 5 located in Tell City, Indiana won supplier of the year.

James Newsome | Waupaca Foundry

#award #iron-casting #tellcity

Waupaca Foundry

Iron Castings - Mar 31, 2014

Marinette Plant 4 Receives Award | Waupaca Foundry

Waupaca Foundry's Plant 4 in Marinette, Wis. was recognized by Nissin Brake as its most improved supplier.

James Newsome | Waupaca Foundry

#automotive #award #iron-casting #marinette #supplier

Waupaca Foundry

Iron Castings - Dec 22, 2013

5 Ways to Expedite Your Ductile Iron or Gray Iron Casting Quote

Receiving an accurate iron casting quote in the shortest possible time may determine whether you're awarded new business from an OEM. See the 5 ways to make the process as short as possible.

Phil Bodenheimer | Waupaca Foundry

#iron-casting #rfq #supplier

Waupaca Foundry

Iron Castings - Oct 6, 2013

Beyond Price 6 Common Cost Drivers of Gray and Ductile Iron Castings Exposed

What may be seen as a similar casting in size and weight to the buyer may not be viewed the same way by the iron casting producer. See why.

Phil Bodenheimer | Waupaca Foundry

#iron-casting

Waupaca Foundry

Iron Castings - Sep 23, 2013

Fueling the Fire

CEO Gary Gigante shares insights about the future of Waupaca Foundry andÂ praised its workforce for helping shape and drive the successÂ of the gray iron and ductile iron supplier.

MaryBeth Matzek | Insight Magazine

#iron-casting #supplier

Waupaca Foundry

Iron Castings - Aug 25, 2013

5 Reasons Why the Price of Scrap is Volatile

Waupaca Foundry continues to monitor factors affecting the pricing volatility of ferrous scrap that is used to make gray iron and ductile iron castings. Read how this works.

Tony Lewis | Waupaca Foundry

#scrap

Waupaca Foundry

Iron Castings - Jul 15, 2013

The Scoop on Scrap

Waupaca Foundry, along with the rest of the industry, is watching several global factors to understand what ferrous scrap demand and pricing will do next.Unfortunately, there is no clear trend other than continued market volatility. As shown above, scrap prices have trended down since mid-2011, but the price swings from month to month are the real points to watch. In just two months' time, scrap prices can drop and then rise by more than $100 per ton.

Tony Lewis | Waupaca Foundry

#scrap

Waupaca Foundry

Iron Castings - Jul 8, 2013

Light Weighting ... or Right Weighting?

Here at Waupaca Foundry, we love the camaraderie that accompanies the challenges presented by our customers. We take pride and satisfaction in working with our customers to create a product that fits their needs.

Paul Jones | Waupaca Foundry

#lightweighting

Waupaca Foundry

Iron Castings - Apr 29, 2013

Green Sand Molds 101

As children, we learned the basic principles of green sand molding at the beach or nearest sand box. By mixing the right proportions of sand, clay and water, we created stable forms that would withstand the rising tide. In the foundry the tide is a 75-inches-per-second flow of molten iron at 2,600 to 2,800 degree Fahrenheit. Not only must the green sand resist erosion by the aggressive flow of molten iron, it must accurately define the basic shape of the casting.

Greg Miskinis | Waupaca Foundry

#iron-casting

Waupaca Foundry

Iron Castings - Feb 11, 2013

When to Collaborate on Casting Designs

Casting design is a two-part equation that must meet many requirements. The first focus is product functionality; the design and material performance that is needed for the end product on whatever component it is placed on. There is consideration for size, geometry, strength, noise and a host of other expectations that must be met in order to meet the performance requirements.

Steve Ebert | Waupaca Foundry

#iron-casting #oem #vave

Waupaca Foundry

Iron Castings - Jan 28, 2013

Capacity, Pricing, and other Market Dynamics in the Iron Casting Industry

On the front cover of a recent issue of Automotive News, I saw something that struck me. It was a feature article containing an interesting interview with Scott Kunselman, Senior Vice President of Purchasing and Supplier Quality at Chrysler Group. Kunselman was quoted as saying, "If I can build another car, am I willing to pay a couple of pennies more for a part? Absolutely." Very interesting...

Kris Pfeahler | Automotive News

#iron-casting #oem

Waupaca Foundry

Iron Castings - Jan 9, 2013

New Robots in the Family

New innovations are a regular thing at Waupaca Foundry. And this year is no different, with a new 65-liter robotic core machine. As Waupaca Foundry progresses with core cell automation, new cell installations now include robotics. That's the case with the newly installed L-65 robotic core cell running in the cold box core room at Plant 2/3 in Waupaca, Wisconsin. The new robotic core cell offers different types of pick-offs, including a vacuum head to remove a core from the core box without physically gripping it.

Randy Hillskotter

#innovation #robotics #waupaca

Waupaca Foundry

Iron Castings - Dec 17, 2012

Building Expansion Underway at Marinette Ductile Iron Foundry

Waupaca Foundry expanded their ductile iron castings manufacturing plant in Marinette, Wisconsin adding more than 12,000 SQFT. See how this benefitted their iron castings manufacturing and their employees.

Dan Korpi | Waupaca Foundry

#marinette

Waupaca Foundry

Iron Castings - Dec 8, 2012

Understanding the Parting Line

Learn how parting line best practices help to improve mold quality at Waupaca Foundry.

Shelby Applegate | Waupaca Foundry

#iron-casting

Waupaca Foundry

Iron Castings - Sep 1, 2012

Waupaca's Mold Innovation

Waupaca Foundry found a way to double the number of castings it could make per mold for a complex bedplate job.

Modern Casting

#automotive #iron-casting #supplier #wfnews

Waupaca Foundry

Iron Castings - Jun 5, 2012

Casting Innovation Gains More Support | Waupaca Foundry

Collaboration leads to innovation. That's been the belief and practice for more than 50 years at Waupaca Foundry. The most recent example was a design collaboration to tackle a customer's challenge. The result was an award-winning casting redesign that is lighter, stronger and more cost-effective.

Nick Kern | Waupaca Foundry

#iron-casting #tellcity

Waupaca Foundry

Iron Castings - May 31, 2012

Materials Outlook For Scrap Metal Supply

Waupaca continuously monitors global demand for scrap metal, paying particularly close attention to rates for No. 1 Heavy Melt and Shredded scrap—two main ingredients in our gray iron. Sources reported a year over year (1/2010-9/2010 vs. 1/2011-9/2011) four-million-ton-plus increase in the exporting of U.S. scrap metal, primarily to China, Taiwan and Turkey. The equivalent of a 28 percent increase from one-year prior, this high demand in the export market has taken its toll on materials prices and surcharges.*

Tony Lewis | Waupaca Foundry

#materials

Waupaca Foundry

Iron Castings - Jan 16, 2012

Waupaca Foundry's Etowah Ductile Iron Foundry Rapidly Expanding

Since Waupaca Foundry's Etowah, Tenn. ductile iron foundry resumed operations in the Fall of 2011, the iron casting supplier has been rapidly expanding to handle new assets. What was built as a gray iron facility in 2001, Plant 6 will be moving into 2012 with the addition of state-of-the-art equipment to produce ductile iron, a set of custom-engineered core machines, and three new buildings.

Mike Nikolai | Waupaca Foundry

#etowah #expansion #iron-casting #wfnews

Waupaca Foundry

Iron Castings - Jun 10, 2011

Casting Central to Hydrant Revolution

OEM startup Sigelock is out to change the way fire hydrants are designed and operated, and a metal casting made by Waupaca Foundry is helping make it happen.

Metalcasting Design & Purchasing

#iron-casting #wfnews

Waupaca Foundry | PartingLINE

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The 74th World Foundry Congress

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Underground Hero

THROUGH THE EYES OF A METALCASTER

Outstanding Achievement

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Best Casting Conversion Award

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National Technology Day

3-ways vehicles are reducing weight

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Waupaca Foundry at NEWCAST in Germany

Lightweighting achieved through Design Optimization and High-Strength Ductile Iron

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Building for the Future

Defining Automation's Role in 'Future' Manufacturing

Hurricanes Deliver Shock to Scrap Metal Market

Waupaca Foundry among Top 16 for 'Coolest Thing Made In Wisconsin' contest

Waupaca Foundry gains boiler recertification

Air disc brakes likely to become most popular option, but drums 'will not go away'

Waupaca Foundry receives awards for casting, engineering

Driveline Differential Case Loses Weight | Waupaca Foundry

Markets Served

Trusted Supplier of Commercial Vehicle Iron Castings

Trusted Supplier of Automotive Iron Castings

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Waupaca Foundry Named John Deere 'Partner' Supplier

Cut the weight | Move more freight | Truck News

Ricardo-Designed Ultra-Lightweight Driveline System

Visit Waupaca Foundry at IZB 2016 Booth 4203 Hall 4

Visit Waupaca Foundry at the 2016 InnoTrans Technology Fair

Waupaca Foundry lightweight ductile iron knuckle increases suspension strength

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