A New Zealand startup may be redefining how engineers think about short-run metal part production. Foundry Lab, founded in 2018 in Wellington, New Zealand, has developed a system that merges traditional casting principles with Additive Manufacturing (AM) workflows without relying on layered metal deposition.
Its approach, known as Digital Metal Casting (DMC), combines 3D-printed ceramic molds with microwave-powered metal melting. The result is a casting process that requires no tooling, minimal labor, and can deliver a fully dense, production-grade metal part in under eight hours. The company positions this system as a faster and more production-relevant alternative to metal 3D printing, especially for prototyping and low-volume applications.
While metal AM has made impressive strides in recent years, it remains encumbered by cost, complexity, and post-processing demands. DMC offers a different path: casting-quality parts without the typical delays associated with outsourced foundries or die tooling.
Foundry Lab is “one of the more interesting startups” in AM, says Olaf Diegel, Professor of Additive Manufacturing at The University of Auckland, New Zealand. “They are doing something truly different. Rather than competing directly in the AM space, they are using AM to change and streamline the way we do one of the oldest manufacturing methods in the world, sand casting.” The method essentially offers “casting in your own company,” Diegel adds.
Foundry Lab’s system is already in use for functional components such as aluminum brake shoes, with support for additional alloys including zinc and stainless steel. Copper and brass are in development. Rather than aiming to replace additive or subtractive processes, the company targets the underserved space between prototyping and full-scale production. It is a segment where agility, not just design freedom, is the competitive edge.
Industry traction and funding
Foundry Lab has raised approximately $14 million in funding to date. Early support came from WNT Ventures and a $450,000 repayable grant from Callaghan Innovation. A Series A round in 2021 brought in $8 million, led by Blackbird Ventures and joined by GD1, Icehouse Ventures, K1W1, Founders Fund, Promus Ventures, and others. Individual backers include Rocket Lab founder Peter Beck and former Autodesk CEO Carl Bass. The company has since expanded its U.S. footprint, including the opening of a demo facility in California and an initial system deployment with the New Jersey Innovation Institute for defense-related trials.
Positioning within digital manufacturing
Unlike powder-bed fusion or binder jetting, DMC is not additive in the traditional sense. It is casting, updated for speed and automation. What sets it apart is the hands-off nature of the process and the fidelity of the final parts. DMC parts are often ready for functional testing or end-use without extensive post-processing. This makes the method a practical tool for sectors such as defense, motorsport, automotive R&D, and heavy equipment, where design validation and iteration speed are critical.
Limitations remain. The system is currently optimized for metals with lower melting points, and high-volume production is still the domain of conventional die casting. Certification for critical applications will require continued material validation and process control. However, the ability to deliver same-day cast parts in engineering-grade metals positions Foundry Lab as a potential disruptor, not to metal AM itself, but to how and when it is applied.
As the company prepares for its next funding round and scales customer engagement, its impact on the digital manufacturing landscape will depend on how well it integrates into real-world production workflows. For now, it appears to offer a credible alternative to both additive and traditional casting methods for a growing range of applications.
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