The American castings industry has a long and rich history that traces its origins all the way back to the colonial period before the nation was even officially born. As you can imagine, the industry has evolved dramatically through the centuries, shaped by technological advancements, industrialization, and changing economic demands.
Since 1945, Tazewell has specialized in foundry services engineered around our customers’ unique requirements and specifications. We’ve kept pace with the American casting industry, refining our casting processes to accommodate complex parts of virtually all shapes and sizes. Today, with our integrated CNC machine shop, we can take customization and complexity even further with custom machined castings, tackling some of the industry’s most complex products and challenging designs.
Below, we take a look at the history and evolution of the American casting industry – from the country’s founding all the way through to today.
The Origins of the American Casting Industry
The origins of the American casting industry actually predate the official founding of the country. The American castings industry began in the early 17th century with the establishment of small iron foundries in the colonies. The first recorded ironworks in the United States was the Saugus Iron Works (1646) in Massachusetts, which produced cast iron goods such as kettles, tools, and nails.
Early casting in this period relied on iron ore found locally. The process involved smelting iron in a blast furnace to produce molten iron, which was then poured into molds to form various shapes. Common products included:
- Cast iron stoves and components
- Other household items
- Farm tools
- Basic machinery parts
Revolutionary War and Early 19th Century
During the Revolutionary War (1775–1783), the castings industry played a significant role by producing weapons, cannonballs, and other military equipment for the Continental Army. Iron foundries became crucial in supporting American independence efforts.
The early 19th century also quickly growing demand for iron castings expanded with the growth of infrastructure, particularly in the development of railroads, bridges, and steam engines. Cast iron rails, train wheels, and locomotive parts were vital to the westward expansion of the United States.
The rise of steam-powered machinery, especially during the Industrial Revolution (late 18th to mid-19th century), greatly boosted the castings industry. Foundries began producing larger and more complex castings, including machinery components for factories and agricultural equipment.
The Industrial Revolution
The mid-19th century saw advancements in foundry techniques, such as the use of cupola furnaces for more efficient melting of iron and improved molding techniques. The Bessemer process (introduced in the 1850s) allowed for mass production of steel, which also influenced the castings industry.
While iron casting remained dominant, steel casting emerged as a critical industry in the late 19th century. The steel foundries of the era were instrumental in the construction of skyscrapers, bridges, and railroads. The Carnegie Steel Company, founded by Andrew Carnegie, became a major player in this space.
As the U.S. rapidly industrialized, foundries began producing complex machine parts, including gears, valves, and engine components. These were essential for the growth of the automotive, railway, and manufacturing sectors.
During this period, standards for castings began to emerge, making production more uniform and improving quality control. Foundries evolved from small-scale workshops to large industrial complexes
Casting Throughout the 20th Century
The early 20th century saw a boom in the castings industry due to the rise of the automobile. Companies like Ford and General Motors demanded cast parts such as engine blocks, transmission housings, and brake drums in large quantities. Henry Ford’s assembly line innovation dramatically increased the need for standardized and mass-produced castings.
The World Wars led to massive production increases in castings for military equipment, including tanks, aircraft parts, artillery, and naval vessels. The foundries became a crucial part of the defense industry, contributing to wartime efforts. As technology advanced, foundries began experimenting with non-ferrous metals like aluminum and magnesium, which were lighter and more suitable for aircraft and other specialized applications. The demand for these lighter metals became prominent during World War II.
After World War II, the American castings industry saw unprecedented growth due to the post-war economic boom. The rise of consumer goods, construction, and infrastructure projects required large quantities of cast metal products. The automotive and aerospace industries, in particular, drove high demand for precision castings.
In the 1950s and 1960s, the foundry industry began to incorporate automation, mechanizing processes such as molding, core making, and pouring. This led to increased efficiency and reduced labor costs, enabling foundries to produce high volumes of castings more quickly.
The introduction of new casting techniques, such as investment casting and die casting, allowed for more intricate designs and improved the quality and precision of cast products. These methods also reduced material waste and increased the versatility of castings for different applications.
Quality American Sand Casting Solutions Since 1945
No matter your industry or product application, Tazewell Machine Works provides superior American manufacturing quality for rough or machined castings. Our custom casting services are backed by a robust ISO 9001:2015 certified quality control system and over 75 years of excellence delivered from our foundry right here in Pekin, Illinois.
