# Palmer Foundry Inc

This MFR.ID profile was supplied, reviewed, and approved by Palmer Foundry Inc. Originally approved on 9/12/2025; last updated 9/12/2025. Capability data is manufacturer-approved for public sourcing and RFQ use.

## Profile Links

- Canonical profile: https://mfr.io/palmerfoundry
- JSON data: https://mfr.io/palmerfoundry.json

## Company Overview

Palmer Foundry specializes in precision aluminum sand castings, trusted by aerospace, semiconductor, medical, industrial, and energy leaders nationwide. From our 75,000-ft² facility in Palmer, Massachusetts, we pour proprietary aluminum alloys—including VaPore™, HyDuct5™, and Stable-Cast™—engineered for vacuum-tight, dimensionally stable, and corrosion-resistant applications. Our advanced in-house heat treatment and state-of-the-art CMM inspection (using FaroArm Quantum E and Creaform MetraSCAN Black Elite laser scanning) ensure consistent quality and precision. AS9100D and ISO 9001:2015 certified, Palmer Foundry combines cutting-edge casting technologies, sustainability (a 312.5 kW solar array supplies 18% of our power), and North American supply-chain reliability to deliver superior castings directly from Western Massachusetts.

## Quick Reference

- Processes: Sand Casting, Engineering & Design Services, Inspection & Quality Control, Tool & Die (Fixtures & Gages)
- Lead Time: 4-24 weeks
- Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts)
- Location: Palmer, MA 01069
- Employees: 51-200
- Revenue: $15M-$25M
- Founded: 1951
- Contact: info@palmerfoundry.com - +1 413-283-2976
- Verified: Manufacturer Approved

## Capabilities

### Advanced Aluminum Casting Technologies

Palmer Foundry’s Advanced Aluminum Casting Technologies combine vacuum-tight VaPore® pours, Stable-Cast™ dimensional-stability alloys, and high-ductility HyDuct5™ formulations with both green- and no-bake sand molding. Proprietary alloy and process development, in-house MAGMASoft simulation, and Class 2 heat-treat furnaces enable leak-free, near-net castings up to 1,500 lb.

- Process: Sand Casting
- Highlights: VaPore® castings certified ≤ 1 × 10-6 atm-cc/s helium without impregnation, Stable-Cast™ parts show < 30 µm dimensional change after ± 150 °C cycling, HyDuct5™ aluminum achieves > 10 % elongation in sand-cast condition (T6), Cast weights up to 1,500 lb; wall thickness 0.118 – 3 in with raw-casting dimensional tolerances, X-ray/CT performed off-site; helium leak-testing to ASTM E1742 & E499 performed in-house
- Subprocesses: Die Casting, Dimensional-Stabilization Heat Treatment, Alloy & Temper Guidance, Sand Casting, Casting Process & Alloy Development
- Specifications:
  - Casting Simulation Software: MAGMASoft, SolidWorks Simulation - Metal flow, solidification, and shrinkage verified before tooling release.
  - Alloy Families: A356-T6, A357-T6, 319-T6, C355-T6, HyDuct5™, Stable-Cast™ - Melted in 2,000-kg gas-fired furnaces; hydrogen porosity index ≤ 0.12 mL / 100 g.
  - Leak Tightness (VaPore®): 0.000001 atm-cc/s He - Helium mass-spectrometer testing per ASTM E499.
  - Surface Finish (As Cast): 250-984 µin - No-bake silica sand 250 µin; green sand 250-984 µin prior to blast.
  - Maximum Casting Weight: 1500 lb - Maximum single-pour weight in no-bake sand; heavier sections possible with sequential dual-pour gating.
  - Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts) - Duplicate flask lines and dedicated finishing cells support all volumes.
  - Raw Casting Dimensional Tolerance (Typical): 0.016-0.094 in - Per MSS SP-59; finish dimensions held post-machining.
  - Lead Time (First Article): 16-24 weeks - Repeat orders 4-8 weeks depending on alloy and heat-treat.
  - Wall Thickness Range: 0.118-3 in - Thin 0.118-in ribs achievable using chills and vacuum assist; heavy 3-in sections fed by MAGMASoft-simulated risers.
  - Core Binder System: Furan no-bake, Phenolic urethane no-bake, Bentone green sand - Binder chosen for part complexity and surface requirements.
  - Max Part Envelope: 8 ft - Larger assemblies possible via joining.

### Engineering & Design Support Services

Palmer Foundry’s engineering group couples multi-CAD ingestion, high-fidelity flow/FEA simulation, and CNC-verified tool-path generation to accelerate cast-part development from concept to production release. Structured DFM reviews, casting solidification analysis, virtual prototyping, and robust CAM post-processing ensure every design arrives on the foundry floor optimised for quality, cycle-time, and cost.

- Process: Engineering & Design Services
- Highlights: Structured DFM scorecard links design choices to cost drivers, MAGMASoft® and SolidWorks Simulation cut porosity risk by > 80 %, Reverse-engineering pipeline delivers ±0.002 in (±50 µm) accurate solid models
- Subprocesses: DFM / DFA Consulting, Tool & Die (Fixtures & Gages), Casting Solidification & Flow Simulation, Mechanical Engineering Design & FEA, CNC Programming & Post-Processing Services, Scan-to-CAD Reverse-Engineering Workflow
- Specifications:
  - Supported CAD Formats: STEP, IGES, Parasolid, SolidWorks, NX, CATIA, Creo - Native and neutral 3-D models accepted; automatic healing of import errors.
  - Simulation Software Platforms: MAGMASoft v5.5, SolidWorks Simulation 2025 - Validated solvers for casting flow/solidification and structural FEA.
  - Maximum Assembly Size: 118L x 78.7W x 39.4H in (3000L x 2000W x 1000H mm) - Upper envelope for CAD models, simulation meshes, and CAM verification.
  - Documentation Standards: ASME Y14.5-2018, ISO 16792-2021, NASA-STD-8739.6 - Drawings and MBD files issued per latest GD&T and aerospace guidelines.

### Aerospace-Grade Quality Assurance & Testing

Palmer Foundry’s in-house metrology lab—featuring FaroArm Quantum E and Creaform MetraSCAN Black Elite laser scanning—mechanical test center, and certified QMS ensure every aluminum casting meets stringent aerospace requirements. Integrated CMM, spectrometry, NDT, leak, and mechanical testing are tied to AS9100D/ISO 9001 traceability, while real-time SPC dashboards drive CpK ≥ 1.33 in production. Complete FAI/PPAP reporting speeds customer qualification and maintains cradle-to-grave data integrity.

- Process: Inspection & Quality Control
- Highlights: AS9100D & ISO 9001:2015 QMS with electronic lot-level traceability (40-year retention), Dimensional accuracy verification to ±0.002 in using Mitutoyo Crysta-Apex S CMM (27.6 × 39.4 × 23.6 in), Helium mass-spectrometer leak testing to 1 × 10-6 mbar·L/s; pressure-decay up to 10 bar, Real-time SPC (InfinityQS) alarms when CpK < 1.33, backed by automated trend reports
- Subprocesses: Quality-Management Certification & Traceability, Optical-Emission Spectrometry (OES) Alloy Verification, Hardness & Tensile Coupon Testing, 3D Coordinate Measurement, Non-Destructive Testing (NDT), Vacuum & Pressure Leak Testing, Real-Time SPC, Inspection Reporting
- Specifications:
  - Spectrometer Detection Limit: 0.005 wt % - Hitachi OE750 OES; limits apply to Si, Fe, Cu, Mg, Zn, Ti.
  - SPC CpK Alert Threshold: {"unit":"","value":1.33} - InfinityQS triggers hold when CpK < 1.33.
  - Tensile Test Capacity: 11240 lbf - MTS servo-hydraulic frame; ASTM E8 compliance.
  - X Ray CT Resolution: 0.001 in - 225 kV Nikon XT H resolves defects ≥ 0.001 in in 6-in thick aluminum.
  - CMM Measurement Envelope: 39.4L x 27.6W x 23.6H in (1000L x 700W x 600H mm) - Mitutoyo Crysta-Apex S7106 volumetric accuracy 2.5 + 3.0 L/1,000 µm.
  - FAI Report Turnaround: 3-5 days - Includes ballooned drawing, dimensional report, and AS9102 forms.
  - Hardness Scales Supported: Brinell HB10, Rockwell B, Rockwell C - King portable Brinell & Wilson 600 Rockwell testers.
  - Certification Standards: AS9100D, ISO 9001:2015, Aluminum Association — Standards for Aluminum Sand and Permanent Mold Castings (16th Ed.) - Scope covers casting, machining, inspection, and documentation; registrar NSF-ISR.
  - Leak Rate Capability: 0.000001-0.001 mbar·L/s - Hard-vacuum mode reaches 1 × 10-6 mbar·L/s.
  - Dimensional Accuracy (CMM): 0.002-0.002 in - Equivalent metric limit 50 µm.

### Casting Finishing Operations

Palmer Foundry removes gates / risers, performs abrasive blast cleaning, deburrs, installs threaded inserts, and kitts parts so castings ship sand-free, datum-ready, and ready for in-house CNC rough-machining (offered exclusively on Palmer-cast parts).

- Process: Tool & Die (Fixtures & Gages)
- Highlights: Gate / riser skim cuts hold ±0.015 in for reliable downstream fixturing, Glass-bead or Al-oxide blast achieves 492–984 µin Ra surfaces ready for machining or coating, Heli-Coil®, Keensert® and PEM® inserts installed per NASM33537 torque specs, Trim and blast throughput ≤ 8 castings / hr per cell; setup changeovers < 24 h, In-house CNC rough-machining is performed only on castings poured by Palmer Foundry (not a standalone service)
- Subprocesses: 4-Axis CNC Milling (Indexing), Deburring, Abrasive Blasting, Light Mechanical Assembly
- Specifications:
  - Blast Surface Finish Range: 492-984 µin - Glass-bead for cosmetic matte (~ 492 µin Ra); Al-oxide for coating anchor (~ 984 µin Ra).
  - Trim Tolerance (Gate/Riser Removal): 0.015 in - Maintains ±0.015 in on datum pads to speed downstream machining.
  - Throughput (Trim & Blast Cell): 8 castings/hr - Average for 5 lb – 55 lb aluminum housings including gate cut, deburr, and blast.
  - Lead Time – Repeat Cast Trim: 2-3 days - From casting shake-out to shipment after trim, blast, and insert install.
  - Threaded Insert Size Capability: #4-40 UNC up to ½-13 UNC - Installed with pneumatic torque tools and depth gauges; cert sheet logged per lot.

## Certifications

- AS9100D (Type: Certification; Authority: International Aerospace Quality Group (IAQG); Status: Active; Scope: Quality Management System certification for aerospace and precision castings; Expiration date: 2027-08-06; URL: https://www.sae.org/standards/content/as9100d/)
- ISO 9001:2015 (Type: Certification; Authority: International Organization for Standardization (ISO); Status: Active; Scope: Quality Management System covering aluminum casting, machining, and finishing operations; URL: https://www.iso.org/iso-9001-quality-management.html)
- ITAR Registration (Type: Registration; Authority: U.S. Department of State – Directorate of Defense Trade Controls (DDTC); Status: Active; Scope: Registration permitting manufacture of defense-related articles under ITAR controls; URL: https://www.pmddtc.state.gov)
- Nadcap Accreditation (Type: Accreditation; Authority: Performance Review Institute (PRI); Status: Active; Scope: Nadcap special-process accreditation – Welding task group; URL: https://p-r-i.org/nadcap)

## Industries Served

- Medical Devices & Healthcare Equipment: Precision aluminum castings and assemblies for diagnostic, imaging, and surgical equipment requiring vacuum-tight, biocompatible components.
- Electronics & Semiconductors: Near-net-shape, low-porosity aluminum enclosures and frames for semiconductor tools and high-density electronics.
- Industrial Machinery & Heavy Equipment: High-strength cast housings and structural parts for industrial machinery and heavy-equipment OEMs.
- Aerospace & Defense: AS9100D-approved aluminum castings for aircraft systems, defense platforms, and mission-critical sub-assemblies.
- General Manufacturing: Custom engineered castings supporting diverse general-manufacturing applications that demand tight tolerances and rapid prototyping.
- Energy & Power Generation (inc. Renewables): Long-life, corrosion-resistant cast components for turbines, generators, and balance-of-plant power-generation systems.

## Facilities

### Palmer Foundry Main Facility

Located in Palmer, Massachusetts—minutes from major interstate highways—our 75,000-ft² headquarters occupies a 9-acre campus dedicated to high-integrity aluminum alloy casting. Equipped with immersion melting and advanced sand-molding processes, we deliver precision castings fully finished with heat treatment and advanced CMM inspection. Our sustainability commitment includes a 312.5 kW solar array that provides nearly 20% of our facility's electricity, enhancing local reliability and reducing environmental impact for customers nationwide.

- Type: manufacturing_facility
- Headquarters: Yes
- Email: info@palmerfoundry.com
- Phone: +1 413-283-2976
- Address: 22 Mt Dumplin Rd, Palmer, MA 01069, United States

## Verification Status

- Business Entity: Verified 7/10/2025
- Technical Capabilities: Verified 9/12/2025
- Locations & Facilities: Verified 9/12/2025
- Reviews & Ratings: Not yet verified
- MFR.ID Created: 6/11/2025
- Last Updated: 9/12/2025