Bronze Sand Casting
The Federal Group USA is a QMS 9001:2015 Certified manufacturer of bronze sand casting specializing in custom metal components. We support medium- to high-volume manufacturing with a comprehensive solution covering casting, machining, finishing, and assembly.
Request a QuoteThe Federal Group USA acts as your dedicated manufacturing partner to deliver precise bronze casting services that meet strict built-to-print specifications.
Bronze Alloy Selection
We pour aluminum bronze, bearing bronze, naval bronze, and lead-free bronze to match your specific mechanical requirements.
Process Control
Our team controls melting temperatures and sand mold compaction to produce highly consistent castings across large production runs.
Quality Assurance
Our QMS 9001:2015 Certified processes rely on cross-functional inspections and detailed material documentation to verify every part.
Casting Tolerances
We control dimensional tolerances, wall thickness, draft, and core placement to ensure reliable component performance.
Machinery & Technology
We use advanced industrial equipment to support demanding production runs, precise tooling, and accurate pattern making.
Induction Melting Furnaces
We use precise temperature controls to produce clean bronze melts with consistent metallurgical properties.
Automatic Molding Machines
Our high-speed sand molding equipment creates accurate mold cavities and supports repeatable medium- to high-volume production runs.
CNC Machining Centers
We use advanced milling and turning equipment to machine each casting to its exact finished dimensions.
Bronze Alloys for Sand Casting
We pour a variety of high-strength bronze grades to meet strict performance requirements:
- Aluminum bronze
- Bearing bronze
- High-strength bronze
- Naval bronze
- Lead-free bronze
- Other customer-specified copper alloys
Looking for brass castings? We also manufacture custom brass sand castings for applications requiring the strength, corrosion resistance, machinability, and other properties of brass alloys.
Secondary Processes and Finishing Capabilities
We offer comprehensive secondary operations and value-added finishing to deliver complete bronze components ready for installation:
- Machining: Our CNC milling and turning centers bring raw sand castings to final dimensional specifications.
- Tapping and drilling: Our precision hole-making creates accurate threads and mounting points for components designed to fit.
- Deburring: We remove sharp edges and casting flash for safe handling and proper fit.
- Assembly: We combine cast and machined components into finished sub-assemblies to simplify your manufacturing process.
Custom Bronze Sand Cast Components We Manufacture
Bronze sand casting is commonly used for components requiring wear resistance, corrosion resistance, bearing properties, or reliable performance in demanding industrial environments.
- Pump components
- Valve bodies
- Plain bearings
- Bushings
- Gears
- Marine hardware
- Structural fittings
Request a Quote for Custom Bronze Sand Castings
Partner with The Federal Group USA for your bronze sand casting needs, and a dedicated program manager will serve as your single point of contact to ensure we meet your application’s exact performance, material, dimensional, and production requirements.
Submit your drawings, 3D models, material requirements, annual volumes, finishing requirements, and quality specifications, and our team will review your project and identify the appropriate manufacturing solution.
Contact us today to get started on a custom project quote.
Client Testimonials
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David Detuccio2026-08-11The Federal Group has demonstrated professionalism, responsiveness, and a willingness to collaborate during the initial stages of our relationship. Communication has been timely, and they have shown a commitment to understanding our requirements and business expectations. Responsive communication and follow-up. Competitive pricing and commercial flexibility. Good product/service quality during initial orders. Cooperative approach to resolving issues and answering questions. Demonstrated interest in building a long-term partnership. Alanna and Sandor are amazing!Trustindex verifies that the original source of the review is Google.Judd Stretcher2026-08-11Great communication and quality parts at a fair price. They really make sure your happy with your parts.Trustindex verifies that the original source of the review is Google.Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.
