Custom Iron and Steel Casting
Services You Can Rely On

At FC Casting Solutions, we specialize in custom iron and steel castings engineered for demanding industrial and marine environments. Our team has refined every stage of the process–from collaborative design and expert metallurgy to rapid prototyping and precision heat treatment–to deliver fast, reliable casting solutions that meet your project’s performance and delivery goals. With agile manufacturing and a relentless focus on quality, we help you move from concept to production with confidence.

Design & Engineering

Expert Design & Engineering

  • Advanced metallurgical competencies

  • Custom profile geometry development

  • Fast, precise contour mapping

  • 3D and CFD simulation modeling

  • Complete manufacturing process simulation

Our design engineers partner closely with your team to turn ideas into production-ready castings. Even without finalized product drawings, we can rapidly define the required dimensional specifications using advanced simulation tools and hands-on expertise. From there, we move efficiently into a first article run using our on-site pattern shop and agile production process–getting your custom castings ready for field performance faster.

Streamlined Manufacturing

  • Full in-house engineering and metallurgical capabilities

  • On-site CNC-enabled pattern and tooling shops

  • Agile prototyping and first article sampling

  • No-bake molding loop for efficient production

  • On-site heat treatment facilities

Our integrated manufacturing process allows us to move seamlessly from prototype to full-scale production. We identify the right iron or steel alloys and manufacturing methods to achieve both performance and cost efficiency. Castings undergo controlled heat treatment on-site when required to achieve the desired mechanical properties and long-term durability your application demands.

Manufacturing
Excellent Quality

Proven Quality in Every Casting

  • 100% inspection and certification for every casting

  • On-site metallurgy and chemical analysis labs

  • Magnetic particle testing for surface integrity

  • Industrial ultrasound testing for internal soundness

  • Liquid penetrant testing for non-porous surfaces

  • Complete batch traceability via serial numbers

Quality is built into every stage of production. Our team maintains strict control over dimensional accuracy, material composition, and mechanical performance to ensure your custom metal castings meet or exceed project requirements. Through advanced testing and traceability, we help you achieve reliability in the field, while our streamlined processes keep lead times short and your inventory costs low.

Comprehensive Casting Capabilities

  • Wide range of iron and steel alloys

  • Application-based iron and steel alloy development for performance and durability

  • Pattern and tooling design for precision molding

  • Advanced casting rigging systems

  • Casting weight range: 220lb-14,500lb (100kg-6,000kg)

  • Short lead times

  • Strategic North American location for re/near shoring

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