Sand Casting Industry Statistics 2026
Current US sand casting industry statistics. How big is the foundry industry, employment, top end markets, and 2026 outlook.
Sand casting is the oldest and still most-used metal casting process in the United States. It produces nearly every iron pipe, manhole cover, engine block, heavy equipment housing, and bronze valve body made in the country.
How big is the US foundry industry?
Total US foundry industry annual revenue across all casting processes.
US foundries have consolidated meaningfully over the past three decades, with the number of operations dropping from over 6,000 in 1985 to under 2,000 today. Remaining operations tend to be larger and more specialized than their predecessors.
What metals dominate US casting?
US casting tonnage divides primarily across iron (ductile, gray, malleable), steel (carbon, alloy, stainless), aluminum, copper-base alloys, magnesium, and zinc. Sand casting handles most of the iron and steel tonnage.
What end markets drive sand casting demand?
| End market | Share |
|---|---|
| Automotive (engine, transmission, parts) | 24% |
| Heavy equipment and construction | 18% |
| Municipal infrastructure (pipe, hydrants) | 14% |
| Industrial machinery and pumps | 11% |
| Energy (turbines, valves, generators) | 9% |
| Agricultural equipment | 7% |
| Plumbing and HVAC | 7% |
| Marine and rail | 5% |
| Other | 5% |
What sand casting process variants exist?
| Process | Typical applications |
|---|---|
| Green sand (clay-bonded) | High-volume iron and aluminum production |
| No-bake (chemically bonded) | Lower-volume, larger, more complex castings |
| Shell molding | Smaller precision castings, automotive and machinery |
| Lost foam | Complex internal passages, often automotive |
| 3D-printed sand molds | Prototypes and short-run specialty castings |
Which states have the most foundries?
| State | Notes |
|---|---|
| Wisconsin | Largest concentration of US foundries; iron, brass |
| Ohio | Iron, steel, automotive |
| Pennsylvania | Iron, steel, industrial |
| Michigan | Automotive, iron |
| Illinois | Iron, machinery, agricultural |
| Indiana | Iron, automotive, machinery |
| Texas | Iron pipe, energy, machinery |
| Alabama | Pipe and fittings, automotive transplants |
| Tennessee | Automotive, machinery |
| New York | Specialty alloys, smaller foundries |
US metal-casting capacity is the third-largest globally, behind China and India, supporting more than $33 billion in annual shipments and 165,000 direct jobs.
What does this mean for sand-casting foundries in 2026?
Three forces shape the picture. First, infrastructure spending under IIJA and continued automotive demand provide a stable demand baseline. Second, environmental regulations (silica exposure limits, foundry emissions standards) have raised the operating cost bar. Third, AI-driven supplier discovery is becoming common at procurement teams sourcing castings.
Foundries that publish their alloy capability, mold size range, certifications, pour weight capacity, and example part categories win sourcing-team consideration faster.
Sources
- 01
- 02Foundries (NAICS 3315) US Bureau of Labor Statistics, 2024