High-volume ferrous foundries
Gray and ductile iron and steel foundries running moving lines where takt, scrap and pourer availability set the ceiling on output.
Foundries thatrefuse to runblind.
Ferrous and non-ferrous sand, die, permanent-mold and investment casting foundries and die casters between $150M and $30B in revenue, running melt, molding, coremaking, pouring, solidification, fettling and finishing lines.
$150M–$30BCustomer revenue range
6Alloy families
5Casting methods
Built with foundries and die casters melting iron, steel, aluminium, magnesium and copper
Ironhaus GroupMeridian CastingsVulcan DuctileAurora Light MetalsKestrel Die CastingNorthfield Foundry Co.
[PLACEHOLDER] Design-partner names are illustrative until first references are signed.
The plants wherethe loop pays.
Aluminium and light-metal casters
Lightweighting and EV structural programs where hydrogen, inclusions and shrinkage decide whether a megacasting ships.
Die casters
HPDC and LPDC cells where shot profile, die thermal state and porosity are the difference between cycle time and rework.
Investment casting houses
AS9100 and NADCAP work where CT is the verdict, genealogy is contractual and an escape is existential.
Multi-site foundry groups
Groups that want one loop, one evidence model and one set of benchmarks across plants that currently solve everything differently.
Copper and magnesium specialists
Pump bodies, fittings, electrical components and tight-envelope magnesium work where chemistry and pour temperature dominate quality.
Three champions,three approvers,one economic buyer.
01Plant / Operations Director
Owns production rate, quality, scrap, yield and safety. Signs when a single cell improvement clears payback and when the safety story survives contact with EHS.
- Cares about rate, scrap, escapes and workforce
- Wants autonomous, higher-yield casting
- Needs a number, not a narrative
- Economic buyer
- Champion
- Champion
- Approvers
PainBaselineWedgePayback
Annual wedge pain$500k–$5M
Month payback6–12
Cell to start1
Scrap and rework at the wedge cellmeasured
Melt energy per tonnemeasured
Inspection backlog and escape riskmeasured
Labour constraint and overtimemeasured
The five problemsthat start everyconversation.
These are the pains our ICP names before we ask. If none of them is true at your plant, we are probably not the right vendor yet.
- Manual, craft-bound, dangerous pouring and melt control that caps rate and consistency
- Porosity, inclusion, cold-shut, misrun and hot-tear defects driving scrap and recalls
- Sand and core defects and dimensional faults causing rejects and rework
- Heat-to-heat melt chemistry drift and pour-temperature error degrading quality and safety
- Hot, hazardous work and a severe, retiring melter, molder and pourer shortage
Honest disqualificationsaves everyonea quarter.
Art and jobbing foundries
Tiny art or jobbing shops with no repeatable primary casting scope. There is no wedge cell to baseline and no repeat volume to learn from.
Closed integration
Sites unwilling to integrate melt, molding, pouring and inspection systems under IP and security controls. Without data access the loop cannot close.
Dashboard shoppers
Buyers seeking a generic horizontal dashboard rather than a system of action. We are not a BI layer over a historian.
Composite voices frombuyer conversations.
Everything in this plant is inspected after the value is added. We need to know at shakeout, not at the X-ray cabinet.
Simulation told us what should happen. Nothing told us what did happen, heat by heat.
If a robot is going to pour, the safety case has to be airtight before anyone talks about yield.
Design-partner voices are illustrative composites of foundry buyer conversations. [PLACEHOLDER — replace with named references after first case studies.]
3–5
Design partners in the first phase
1
Wedge cell to start
100%
Pilots start in shadow mode
0
Write-backs before a safety review
What a designpartner gets.
Phase 1 · shadow mode
Instrumented baseline on your wedge cell
We measure the real scrap, rework, melt-loss, yield and inspection numbers on the cell over a representative period, using your records as ground truth.
Phase 1 → 2
Golden-set accuracy review
Agent predictions scored against your own inspection results for that alloy and geometry family before anything is recommended to an engineer.
Phase 2
Assist mode with your engineers in the loop
The agent recommends melt, mold, pour and cooling moves and predicts soundness; your metallurgist approves each one and every correction trains the models.
Phase 2 output
Baseline vs. improved KPI report
A defensible before-and-after on first-pass yield, scrap, porosity rate and melt energy — the artefact your finance team will ask for.
Phase 3
Bounded write-back after safety review
Low-risk cells graduate to adaptive control inside approved process windows, with rollback armed and exceptions escalating.
Commercial
Preferential expansion terms
Design partners get preferential pricing on adjacent cells and modules, in exchange for case-study rights once the numbers are in.
Become adesign partner.
We are recruiting three to five paid design partners around one measurable wedge: robotic pour and fill control, X-ray and CT porosity detection, or melt-chemistry optimisation.