How Meloon Foundries Reinvents Sand Casting for the Modern Manufacturer

In today’s competitive manufacturing environment, global supply-chain disruption, increasing cost pressures and demand for rapid, reliable turnarounds mean that precision and consistency aren’t optional—they’re essential. At Meloon Foundries, we understand that every casting isn’t just a piece of metal—it’s a critical component of your business. It’s a commitment to quality, delivery and value.

Built for Performance: Aluminum & Copper-Based Sand Castings

With roots grounded in American manufacturing—and more than 85 years of foundry experience—Meloon Foundries specializes in high-performance sand castings of aluminum and copper-based alloys.  

We cast over 40 distinct alloys and serve more than 200 customers nationwide. Sand Castings

Whether you’re producing a structural component for heavy-duty machinery, a stable base for medical equipment, or a high-conductivity copper casting for industrial applications, we deliver the versatility you need. Our capabilities include:

• Casting weights up to ~1,000 lbs and flask sizes up to 93″ × 93″. See casting weights
• Green sand and no-bake molding processes—ideal for complex geometries, thick walls, and challenging production runs. More on Green Sand
• Value-added services: rapid prototyping, pattern design, heat treating, machining, certifications and in-house quality labs. 

Design & Process: From Concept to Cast

Too often, parts that look good on paper don’t translate easily to cost-effective, high-quality castings. That’s why Meloon emphasizes early collaboration between your design engineers and our foundry experts. Our “Design & Process Guidelines” help ensure your castings are optimized for manufacturability, cost and performance. Learn more about our process guidelines

By thinking of casting early—selecting the right alloy, balancing wall sections, defining tolerances and anticipating machining or finishing needs—you’ll reduce scrap, machining costs, delays and redesigns. It’s casting done right.

Why Sand Casting Still Makes Sense

You might ask: with so many advanced manufacturing and casting technologies available, is sand casting still relevant? The answer: absolutely. As our recent blog “Green Sand Aluminum Casting vs. High Pressure Die Casting” highlights, green-sand casting is often the best fit for many industrial and structural parts because of its design flexibility, broader alloy compatibility and lower tooling cost. Read what’s right for you.

For projects with moderate volumes, complex geometry, thicker wall sections or heavier parts, sand castings can deliver strong mechanical properties, cost-effectiveness and quicker responsiveness than many alternative processes.

Industries We Serve — From Medical to Infrastructure

Our customers span multiple sectors where reliability, performance and consistent delivery matter. For example, medical equipment manufacturers rely on our castings where “stability” isn’t just nice to have—it’s mandatory. Read about deliverying on what you need. We also support architectural, transportation, energy, defence and industrial equipment markets, providing castings built to specification and delivered on time.

Why Choose Meloon Foundries for Your Next Project

• American-based manufacturing: U.S. facility means closer collaboration, shorter lead times and fewer supply-chain surprises.
• Over 40 alloy options: A broad portfolio means you can match material selection to performance needs—not compromise.
• End-to-end services: From rapid prototyping to casting, finishing, machining and inspection—one partner, one quote.
• Engineering support: We don’t just cast metal. We help optimize your part so you get a better outcome—faster and more cost-efficient.
• Quality control you can trust: In-house labs, metallography, certification, and decades of experience backing every project. More about our capabilities.

Ready to Cast Your Success?

If you’re launching a new component, replacing a legacy cast part, or looking to reshore your supply chain, let’s talk. Our team at Meloon Foundries is ready to partner with you—bringing technical insight, manufacturing excellence and real results.

Call us today at (315) 454-3231 or click the “Get A Quote” button at meloon.com to upload your print and start the conversation. Don’t settle for just “a foundry”—choose a casting partner that thinks like you.