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As we head into 2026, American casting and domestic manufacturing in general are enjoying a unique resurgence. In many ways, the domestic industry was already on the rise, largely in response to supply chain disruptions dating back more than half a decade to the pandemic. Throughout 2025, tariff turbulence has further upended the previous status quo of offshoring.

At Acme Foundry, we believe this is not a cyclical fluke, but a structural shift. Higher raw-material costs, evolving tariff policies, supply chain volatility, regulatory changes, and an emphasis on resilience are making domestic casting not only more attractive, but often the best choice.

Below we lay out the forces driving this shift, the challenges of overseas sourcing, and why American manufacturers are better positioned than ever – particularly in the case of well-established foundries like Acme, delivering high-quality results since 1905.

Reshaping U.S. Manufacturing in 2025: Tariffs, Raw Material Costs, and Uncertainty

As we head into 2026, let’s recap what 2025 brought to the table for American manufacturers:

The Direct Cost of Tariffs

Over recent years, the U.S. has significantly increased tariffs on a number of imported raw materials and finished goods, especially metals and metal inputs. For example:

• Steel and aluminum tariffs have been raised, with levels such as 50% on steel and aluminum in many cases.

• Tariffs on copper and related inputs have also been under review or increased.

• Policies requiring that steel be “melted and poured” in the U.S., and aluminum “smelted and cast” in the U.S., to qualify for certain duty-free exemptions are gaining ground, effectively forcing more domestic supply chain integration.

These tariff regimes significantly raise the landed cost of importing raw materials and components – not just the cost itself, but the risk that duties will change, exemptions will be narrowed, or “loopholes” will be closed.

Rising Raw Material Costs

Of course, the cost of tariffs is only one part of the story. Raw material prices globally are volatile, driven by supply constraints, energy costs, environmental regulations, and geopolitical risk. Some of the dynamics:

• Aluminum prices in the U.S. are under pressure due to both global supply constraints and U.S. import tariffs. The Midwest premium for aluminum has surged massively.

• Steel and aluminum tariffs make foreign sourcing more expensive, even beyond the base import duty – through additional shipping costs, delays, quality control, and risk of non-compliance.

When you combine these input-cost increases with transport, customs, logistics, and risk, it becomes harder for overseas suppliers to remain cost-competitive in a reliable way. In other words, the unseen costs, complications, and all the headaches you deal with in offshoring can easily outweigh the upfront cost of quality American castings.

Adding Uncertainty and Risk to the Equation

Overseas supply chains have seen increased risk in recent years due to product/material shortages, port shutdowns, geopolitical disputes, etc. 2025’s ever-changing trade landscape and shifting tariff rates only add to the uncertainty and risk:

• Tariff Volatility – A supplier overseas could be subject to new duties or changes in trade policy at any time. What seems cheap today may become costly tomorrow.

• Delays and Logistic Risks – Shipping delays, port congestion, customs hold ups (especially with stricter documentation or compliance rules), and disruptions due to geopolitical tensions or pandemics are no longer rare outliers but recurring risks. Firms now often build in buffers (inventory, alternative suppliers) to account for these delays.

• Regulation and Origin Rules – Increasingly, U.S. trade policy and procurement requirements impose strict “rules of origin,” i.e. for materials to be considered domestic or duty-exempt, they must be processed to certain standards in the U.S. That includes most foundry processes: steel being melted, poured, cast, etc. These rules reduce domestic vendors’ ability to source overseas components without the risk of increased duties in the future.

When you break it all down and account for tariffs, delays, quality issues, costlier shipping, potential reworks, compliance risk, and the need to hold more inventory…the “low cost” overseas sourcing often loses its edge in total landed cost, or your total cost of ownership (TCO). That’s why more and more companies are re-evaluating their offshore foundry work, especially in heavy equipment or critical components which carry the highest potential for future supply risk and added cost.

Acme Foundry: Positioned for Future Stability and Ongoing Success

At Acme Foundry, we see the opportunities clearly – and we’ve been investing to meet them. Here’s how we align with the evolving needs:

• We operate with high standards of material sourcing and process control, ensuring traceability and good metallurgical properties.

• Our facility is focused on responsiveness: we maintain capacity to serve both high-volume long-runs and smaller batches or prototype work.

• We understand that lead time matters – we keep inventory buffers, efficient furnace cycles, and strong supplier relationships to reduce risk.

• We are committed to cost optimization, via energy efficiency, waste reduction, automatic process controls, and lean operations.

• We stay close to policy / regulatory changes, so we can help customers anticipate duties, origin rules, etc., rather than having surprises later.

Dependable American Foundry Casting Services Since 1905

The case for American casting and manufacturing is stronger than it’s been in many years. Tariffs, raw material shortages, logistic risk, and a growing premium on resilience and traceability make reliance on overseas supply chains increasingly risky. For many customers, the lowest initial bid won’t remain lowest once you factor in duties, delays, quality risk, and the cost of uncertainty.

If you want parts you can count on, delivered predictably, with well-documented materials and a partner ready for the changes ahead, there has never been a better time to source American castings.

Are you maybe too focused on your upfront cost per part?

When comparing domestic foundries versus offshore suppliers, the conversation often starts (and sometimes unfortunately ends) with, “What is the cost per part?” No doubt it’s a crucial consideration, plus it’s one that’s easy to see and measure upfront.

But that calculation ignores a whole list of other potential costs and complications that come with overseas suppliers. Plus it’s a line of thinking that has left many domestic sellers high and dry at some point in the last several years due to supply chain disruptions.

If you zoom out and look at the full product life cycle, the larger supply chain, the potential for delays, the other risks involved… you’ll start to see how reshoring your iron casting work to trusted U.S. foundries like Acme can actually reduce your total cost of ownership (TCO), especially in the medium to long term.

The Downsides of Offshoring: What the Traditional “Cheap Part” Argument Misses

It’s no secret that foundries in China and throughout Southeast Asia typically appear cheaper on paper. Labor is far less, raw material costs are usually lower as well as operational costs, plus currency arbitrage can work in your favor. But that’s only the first chapter of the story.

As your project unfolds, you run a number of risks by relying on iron casting foundries halfway around the world:

• Logistics and Freight Challenges – International shipments bring higher base costs plus unpredictable surcharges, demurrage fees, customs delays. What seemed like savings can vanish when shipping costs spike or schedules slip.

• Extended and/or Unreliable Lead Times – Worse when demand fluctuates or designs change. Long overseas lead times limit flexibility.

• Quality Control and Rework – When you’re far away, identifying defects late is costly. Rejected parts, returns freight, or worse, customer failure in the field.

• Communication Friction – Time zones, language differences, slower feedback loops can slow down problem solving.

• Inventory Carrying Costs – To avoid stockouts, many companies over‐order or carry extra safety stock from overseas; that ties up capital and storage.

• Supply Chain Risk and Disruptions – Global supply chains remain susceptible to geopolitical risk, pandemics, transportation bottlenecks, trade policy changes, rising tariffs—all of which can blow past “cheap base cost” assumptions.

Quality American Casting Solutions Since 1905

Reshoring your iron casting work is a strategic move that sets your business up for ongoing success. If you’re evaluating casting suppliers this year, do more than compare line-item costs. Build a full TCO model, ask about quality systems, communication practices, and logistical transparency. And when you do, Acme Foundry is ready to earn your trust, deliver consistency, and help you simplify your supply chain with quality Made in the USA gray iron castings.

“Are gray iron foundries sustainable? What about cast gray iron products in general?” These concerns resonate strongly with many of today’s foundry customers. Whether you’re seeking to minimize the carbon footprint of your products or you’re just trying to keep on top of ever-stricter environmental regulations, sustainability is seen as increasingly important throughout the modern manufacturing space.

At Acme Foundry, Inc., our 120-long legacy in Coffeyville, Kansas since 1905 blends tradition with efficiency to deliver sustainable casting solutions that benefit both the environment and our customers’ bottom lines.

Acme’s Commitment to Casting Quality and Sustainability:

Green Sand Molding – A relatively sustainable foundry process, offering manufacturing flexibility and scalability with minimal resource overhead.

Integrated Core Room – In-house sand core fabrication ensures dimensional accuracy and reduces rework, improving yield and reducing waste.

Defect Mitigation Systems – Techniques targeting shrinkage, blowholes, sand inclusions, and other casting defects keep rework low and quality high .

Integrated CNC Machining – The Magic Circle Machining division streamlines post-casting workflows, diminishing transport and redundancies.

ISO 9001:2015 Quality Management – Our ISO 9001 certified quality management system ensures consistent performance, minimized defects, and optimized processes across all operations.

Acme’s Lean and Green Gray Iron Foundry Processes:

Efficient, Cost-Effective Casting with Green Sand Molding

Acme leverages green sand molding, a traditional process that remains both economical and agile. Crafted from olivine sand, bentonite clay, water, and a small portion of additives, green sand is cost-effective, widely available, and adaptable to complex shapes. This simplicity allows quick setup, high capacity runs, and minimal tooling, contributing significantly to material and energy efficiency.

Material Properties that Support Sustainability

Gray iron’s thermal stability allows castings to withstand extreme temperature changes without fracturing. Outstanding compressive strength makes for durable, long-lasting products. So the material inherently minimizes damaged products and waste. Furthermore, gray iron’s excellent vibration damping (low NVH) also not only enhances user comfort but reduces energy waste in machinery, slightly adding to its green material properties in industrial applications.

Learn more in our previous article: Physical and Mechanical Advantages of Gray Iron Material.

Lean, Integrated Foundry Practices

Acme integrates core making, molding, casting, and machining (via our Magic Circle CNC machining division) within one lean workflow. This integration minimizes transport, scrap, and energy waste, delivering operational efficiency that’s both cost-effective and environmentally responsible.

Rigorous Quality Control Reduces Scrap

A robust quality assurance framework in accordance with ISO 9001:2015 certification helps Acme reduce waste by ensuring accuracy at every stage. From pattern inspections to defect prevention strategies (managing shrinkage, blowholes, inclusions, etc.), this vigilance avoids costly rework and material waste.

Resilient Domestic Supply Chain Reduces Carbon Footprint

By producing domestically, Acme avoids the carbon-intensive and unpredictable nature of overseas shipping. Acme’s ability to deliver promptly, maintain inventory agility, and collaborate closely with each client further enhances the sustainability and responsiveness of our casting services, along with your ongoing supply chain.

Learn more in our previous article: Strengthen Your Supply Chain with American Iron Casting.

Quality American Gray Iron Foundry Services Since 1905

Gray iron foundries like Acme are focused more than ever on sustainable casting solutions. Founded at the turn of the 20th century, our company strives to exemplify how traditional manufacturing can evolve responsibly.

Through lean, integrated processes, high-quality standards, and a commitment to U.S.-based production, Acme Foundry delivers durable, efficient, and environmentally conscious casting solutions, supporting both customers and the national economy.

Acme Foundry specializes in the manufacturing of gray iron castings – a material that offers outstanding thermal properties, damping characteristics, and excellent strength combined with ease of workability and machinability. That makes it ideal for a wide range of industrial product applications, from housing materials and hydraulic parts to machine bases and various components. 

• Industrial valves and fittings
• Compressors, pumped and other pressurized systems
• Commercial construction equipment
• Power plant components (e.g. diesel engine components)
• Various vehicle and transportation system products

Along with ductile iron, gray cast iron is one of the most commonly used materials for a wide range of machinery in industrial manufacturing applications. We compare the two materials below, along with more of the common industrial manufacturing applications.

The Advantages of Gray Iron Casting vs. Ductile Iron Casting

1. Improved Vibration Damping – Compared to ductile iron material, gray iron dampens vibrations more effectively. This is a critical attribute for precision machining applications that require minimum vibration to achieve close tolerances, as well as a multitude of applications that require reduced NVH attributes (noise, vibration and harshness).
2. Increased Machinability – As a material, gray cast iron is much easier to machine than ductile iron. This is due to the metallurgical properties of gray iron, which allow it to be precision CNC machined faster, more reliably and consistently.
3. Decreased Production Costs –  It’s typically easier to work with gray iron material in both casting and machining. That means gray iron can offer cost savings in industrial applications that do not require the improved ductility or impact strength of ductile iron.

Common Industrial Product Applications for Gray Cast Iron

As a readily available, lightweight, and affordable metal, gray cast iron is the ideal material for a wide range of commercial and industrial sectors. For example, any manufacturing application that requires enhanced vibration damping (e.g. equipment frames and fixtures). Other common product applications for gray cast iron include:

Industrial Pipes and Fittings

Gray cast iron pipes and fittings are used throughout the industrial sector for plumbing, drainage, and cooling systems. It’s a cost-effective material for manufacturing custom pipes and fittings while offering good corrosion resistance and outstanding strength to stand up to tough factory environments.

Compressor Housings and Hydraulic Pump Components

Grey iron is a commonly used material for industrial compressor housings and cylinders, as well as various hydraulic pump parts. With exceptional compressive strength, the material is able to reliably withstand the high pressures and vibration generally inherent in these applications.

Machine Mounts and Structures

The exceptional vibration damping properties of gray cast iron make it especially well-suited for the fabrication of machine tool structures, bases, and mounts. Not only does the material help reduce noise and vibration, it can also enhance machine precision and reduce manufacturing errors.

Other Industrial Machinery Components

Gray iron is commonly used to manufacture many other various industrial components and machinery parts such as gears, pulleys, and machine housings. Gray iron’s damping properties help keep factory workplaces safer, quieter, and more comfortable, while also offering great wear resistance and durability for an extended service life.

Agricultural and Heavy Equipment Parts

Gray cast iron is also commonly used in various agricultural machinery components such as plow shares, tillers, related mounts and brackets, other tractor parts, as well as irrigation system components. The material’s damping properties combined with its wear resistance and compressive strength make it ideal for commercial agricultural and farming applications.

Why Choose Gray Iron as a Manufacturing Material?

In addition to the application-specific benefits discussed above, gray iron offers a number of general material advantages. It exhibits outstanding thermal properties, great compressive strength, and exceptional damping properties which make it well-suited for applications of noise, vibration, harshness (NVH) reduction. Learn more about the unique material advantages of gray iron in our previous blog – Physical and Mechanical Advantages of Gray Iron Material.

Quality American Casting Services for Industrial Parts and Components

Acme is one of the nation’s leading foundries specializing in industrial parts and similar high-performance castings. Established in 1905, our company is backed by more than 120 years of casting experience and superior American craftsmanship.

The American manufacturing industry continues to transform in 2025, largely driven by a complex web of tariffs, trade negotiations, and a renewed focus on domestic production. The casting sector is no exception, relying on an international network of suppliers for raw materials, machinery, and tooling components.

As a Kansas-based leader in gray iron casting since 1905, Acme Foundry sees these industry-wide shifts creating both supply chain challenges and new reshoring opportunities. Backed by more than 120 years of experience in producing quality gray iron castings in many different economic environments, our company is better poised than many of our competitors to navigate the emerging American manufacturing landscape.

2025 Tariffs and the American Manufacturing Landscape

In 2025, the U.S. has implemented a 10% universal tariff on imports, a policy aimed at revitalizing domestic manufacturing and reducing the trade deficit. The blanket tariff has been accompanied by sector-specific tariffs, such as those targeting raw steel and aluminum materials.

While the tariff rates and other details are constantly changing, many customers are foreseeing increased prices for critical materials and equipment. As such, reshoring is becoming more economically competitive than ever. Based out of Coffeyville, Kansas for more than 12 decades, Acme Foundry is well positioned to serve customers seeking to reshore their gray iron castings and foundry work.

The Reshoring Trend: Opportunities and Challenges

The current tariff regime has accelerated the reshoring trend, with companies seeking to mitigate risks and costs associated with global supply chains. Beyond avoiding tariffs, reshoring offers many benefits such as improved supply chain resilience, faster time-to-market, and easier communication with your manufacturer.

However, reshoring is not without its challenges. Companies must navigate higher domestic production costs, labor shortages, and the need for technological investments to match the efficiencies of offshore manufacturing. Acme Foundry works closely with our customers to meet their expectations, exceed the quality they expect, and simultaneously keep costs at a minimum.

Acme Foundry: A Century-Old Leader in American Manufacturing

Amid this evolving landscape, Acme Foundry stands out as a prime example of American manufacturing excellence. With over a century of experience, Acme specializes in producing complex, cored, and engineered gray iron castings. Our comprehensive services span from engineering and design to machining, assembly, and testing, offering turnkey solutions for clients.

Acme’s in-house CNC machining capabilities through our Magic Circle Machining division enable the production of precision machined castings ready for immediate use. Our ISO 9001:2015 certification underscores a commitment to quality and consistency for every custom cast product.

Why Acme Foundry Is Poised to Lead in the Reshoring Era

As companies reevaluate their manufacturing strategies in response to the current tariff environment, Acme Foundry offers several advantages:

• A U.S.-Based Manufacturing Partner – Being U.S.-based allows for closer collaboration between product engineers and the manufacturing team, facilitating real-time quality control and faster iterations.
• Comprehensive Foundry Services – Acme’s end-to-end capabilities reduce the need for multiple suppliers, streamlining the production process and reducing potential delays. Our capabilities also include custom CNC machined castings, streamlining another complex step in your supply chain.
• Superior Quality Assurance – Our ISO certification and century-long track record provide assurance of product quality and reliability.

120 Years of Quality American Foundry Services

Acme Foundry has remained one of leading sources of quality Made in the USA cast iron products since 1905. Our unmatched experience combined with commitment to quality and craftsmanship equates to superior products backed by a more reliable supply chain.