Precision Pattern-making & Casting Services
What We Do
Farrar Corporation specializes in producing quality ductile iron sand castings from our state-of-the-art pattern shop and foundry in Norwich, Kansas. Our production facilities are streamlined to tackle the entire manufacturing process with precision results: from pattern-making and prototyping to full-scale production runs of CNC machined castings.
Custom Pattern-Making Services With ISO-Certified Quality & Results
At Farrar Corporation, we believe the quality of a casting is determined by the pattern from which it’s drawn, and we take pride in delivering the highest-quality pattern and casting services possible.
Every new project begins in our fully integrated pattern shop located in Norwich, Kansas. Our ISO 9001:2015-certified facility is strategically designed to enable us to manufacture tooling, pour casting, and machine casting in one location.
Keeping the entire process inside our walls lets us control quality, protect timelines, and lock in cost certainty while producing patterns that deliver superior casting performance.
Expert Prototype Manufacturing With Advanced CAD Modeling Services
Many of our current customers require prototypes to test fit, form, and function of new designs without the large capital outlay for a full production pattern. Through our industry relationships, we are capable of producing small prototype runs through advanced engineering, CAD modeling, and efficient turnaround times. This helps you prove out your designs before moving into production.
Based on the 3D model and simulation outputs, we can now produce small prototype runs utilizing 3D-printed sand technology for molding. We can also 3D print replica models of your parts.
The Farrar Design Process
When speed and proof-of-concept matter, our engineering team works directly in SOLIDWORKS and validates each design with MAGMASOFT solidification modeling before a single ounce of iron is poured.
Once simulations are green-lit, we machine the tooling in-house and generate production-ready toolpaths in MasterCAM, giving you dimensionally sound prototypes, reducing errors and outsourcing delays.
Turnkey Ductile Iron Castings
Our straight-line workflow, starting at digital simulation and pattern building, to molding and metal pour, stays inside one campus. If you require your casting to be machined, we’ve got you covered as well. The ductile-iron castings we pour weigh between 5 to 75 lbs and fit in our 20×24-inch flasks on one of our three Roberts Sinto automatic molding lines. Farrar can help with production volumes of up to 50,000 EAU while producing every ductile iron grade, such as 65-45-12, 80-55-06, and 100-70-03. Need something a little stronger? We can also help you with all grades of Austempered Ductile Iron (ADI).
You share the prints or a CAD; we import it, design the tooling, simulate the gating and risering design, machine the matchplate internally, and pour first-article castings before finalizing full production runs for years to come.
We are here to answer any of your questions. Please fill out the form, call or email us. Send us your RFQ package. You are our top priority and we will respond as quickly as we can.