--- title: Our Process | Phenix Foundry description: Learn about our Casting Process from drawing to shipment. Our disciplined, repeatable casting process is essential to achieving consistent quality... image: https://www.phenixfoundry.com/hubfs/Our%20Process/Test%20Parts%20-%20Pouring%20sample%20iron%20castings%20at%20our%20Phenix%20Alabama%20foundry%20-%202.jpg --- [Skip to the main content.](https://www.phenixfoundry.com/our-iron-casting-process#main-content) - [334-298-0441](tel:3342980441) - [Request a Quote](https://www.phenixfoundry.com/contact-us) [![Phenix Foundry - ductile iron castings and gray iron castings specialist - 2](https://www.phenixfoundry.com/hs-fs/hubfs/Phenix%20Foundry%20-%20ductile%20iron%20castings%20and%20gray%20iron%20castings%20specialist%20-%202.png?width=380&height=151&name=Phenix%20Foundry%20-%20ductile%20iron%20castings%20and%20gray%20iron%20castings%20specialist%20-%202.png "Phenix Foundry - ductile iron castings and gray iron castings specialist - 2")](https://www.phenixfoundry.com?hsLang=en) [![Phenix Foundry - ductile iron castings and gray iron castings specialist - 2](https://www.phenixfoundry.com/hs-fs/hubfs/Phenix%20Foundry%20-%20ductile%20iron%20castings%20and%20gray%20iron%20castings%20specialist%20-%202.png?width=378&height=150&name=Phenix%20Foundry%20-%20ductile%20iron%20castings%20and%20gray%20iron%20castings%20specialist%20-%202.png "Phenix Foundry - ductile iron castings and gray iron castings specialist - 2")](https://www.phenixfoundry.com?hsLang=en) - [Gray Iron Casting](https://www.phenixfoundry.com/gray-iron-castings) - [Ductile Iron Casting](https://www.phenixfoundry.com/ductile-iron-castings) - [Capabilities & Services](https://www.phenixfoundry.com/capabilities-services) - [Machining](https://www.phenixfoundry.com/machining) - [Paint & Coating](https://www.phenixfoundry.com/paint-coatings) - [Weldment Conversion](https://www.phenixfoundry.com/weldment-conversion) - [Our Equipment](https://www.phenixfoundry.com/our-equipment) - [About](https://www.phenixfoundry.com/about) - [About Us](https://www.phenixfoundry.com/about) - [History](https://www.phenixfoundry.com/history) - [Our Process](https://www.phenixfoundry.com/our-iron-casting-process) - [Green Sand Molding](https://www.phenixfoundry.com/green-sand-molding) - [Brochure](https://www.phenixfoundry.com/brochure-download) - [News & Events](https://www.phenixfoundry.com/news-and-events) - [Contact](https://www.phenixfoundry.com/contact-us) Toggle Menu Toggle Menu - [Gray Iron Casting](https://www.phenixfoundry.com/gray-iron-castings) - [Ductile Iron Casting](https://www.phenixfoundry.com/ductile-iron-castings) - [Capabilities & Services](https://www.phenixfoundry.com/capabilities-services) - [Machining](https://www.phenixfoundry.com/machining) - [Paint & Coating](https://www.phenixfoundry.com/paint-coatings) - [Weldment Conversion](https://www.phenixfoundry.com/weldment-conversion) - [Our Equipment](https://www.phenixfoundry.com/our-equipment) - [About](https://www.phenixfoundry.com/about) - [About Us](https://www.phenixfoundry.com/about) - [History](https://www.phenixfoundry.com/history) - [Our Process](https://www.phenixfoundry.com/our-iron-casting-process) - [Green Sand Molding](https://www.phenixfoundry.com/green-sand-molding) - [Brochure](https://www.phenixfoundry.com/brochure-download) - [News & Events](https://www.phenixfoundry.com/news-and-events) - [Contact](https://www.phenixfoundry.com/contact-us) # Our Process   ![parallax image](https://www.phenixfoundry.com/hubfs/Banners/Casting%20Process%20at%20our%20Phenix%20Alabama%20Foundry.jpg) ## Casting Process: ### From Drawing to Shipment A disciplined, repeatable casting process is essential to achieving consistent quality, predictable lead times, and cost control at scale. At Phenix Foundry, each project follows a structured path—from initial design review through production and finishing—supported by in-house tooling development, controlled pouring practices, and integrated downstream capabilities. The result is a practical, production-focused approach aligned with real-world operating demands. ## Full Process Overview View the end-to-end details of our casting process ![Engineering Drawing CAD - Review for Iron Casting at our Alabama Foundry 2](https://www.phenixfoundry.com/hubfs/Our%20Process/Engineering%20Drawing%20CAD%20-%20Review%20for%20Iron%20Casting%20at%20our%20Alabama%20Foundry%202.jpg) ##### ** Design Review** Submit your **engineering design** (2D or 3D), **manufacturing drawings**, or **existing tooling.**  We can also assist with [weldment-to-casting conversion](https://www.phenixfoundry.com/weldment-conversion?hsLang=en) ![Model Creation - Part Model Developed from Geometry to create Casting Mold](https://www.phenixfoundry.com/hubfs/Our%20Process/Model%20Creation%20-%20Part%20Model%20Developed%20from%20Geometry%20to%20create%20Casting%20Mold.jpg) ##### ** Model Creation** A **part model** is developed to reflect **final geometry**, **material** requirements, and **performance** expectations. ![Tooling Model Creation at our Phenix Alabama Iron Foundry](https://www.phenixfoundry.com/hubfs/Our%20Process/Tooling%20Model%20Creation%20at%20our%20Phenix%20Alabama%20Iron%20Foundry.jpg) ##### ** Tooling Model Creation** **Patterns, tooling,** and **molding methods** are developed to **support repeatability** and **dimensional control** in production. ![Gating Development for Iron Casting at our Alabama Foundry](https://www.phenixfoundry.com/hubfs/Our%20Process/Gating%20Development%20for%20Iron%20Casting%20at%20our%20Alabama%20Foundry.jpg) ##### **Gating Development** **Gating** andfeeding systems are refined to **ensure proper metal flow, minimize defects**, and **support casting** **integrity.** ![Test Parts - Pouring sample iron castings at our Phenix Alabama foundry - 2](https://www.phenixfoundry.com/hubfs/Our%20Process/Test%20Parts%20-%20Pouring%20sample%20iron%20castings%20at%20our%20Phenix%20Alabama%20foundry%20-%202.jpg) ##### ** Test Parts (Trial Pour)** Initial pours—typically 1 to 10 parts depending on complexity—**validate tooling** and **process assumptions.** ![Mold Production for Green Sand Molding at our Alabama Foundry](https://www.phenixfoundry.com/hubfs/Our%20Process/Mold%20Production%20for%20Green%20Sand%20Molding%20at%20our%20Alabama%20Foundry.jpg) ##### ** Mold Production** **Molds and cores** are produced ([green sand molds](https://www.phenixfoundry.com/green-sand-molding?hsLang=en) and sand cores), assembled, and prepared for pouring. ![Pouring Molton Iron at Phenix Foundry](https://www.phenixfoundry.com/hubfs/Our%20Process/Pouring%20Molton%20Iron%20at%20Phenix%20Foundry.jpg) ##### ** Pour Parts** **Molten iron is poured under controlled conditions.** While the overall process remains consistent, material treatment varies by grade. ![Post-Casting Finishing](https://www.phenixfoundry.com/hubfs/Versa%20Cards/Post-Casting%20Finishing.jpg) ##### **Inspect & Clean** Castings are separated from sand and gating, then **cleaned through blasting and hand grinding.** Final inspection confirms dimensional and quality requirements. ![Cast Parts - Machining Services-2](https://www.phenixfoundry.com/hubfs/Versa%20Cards/Cast%20Parts%20-%20Machining%20Services-2.jpg) ##### ** Machining & Finishing** If needed, we offer machining, surface prep/coating & painting through our affiliate [Metal Goods Manufacturing](https://www.metalgoodsmfg.com/services)—delivering **finished parts to your specifications** with **tight tolerances** and **consistent quality!** ## Get started today! Drop us a line or request a quote! 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