Balerion Principal Aidan Daoussis sits down with David Moodie, Founder & CEO of Foundry Lab, to discuss digitized metal casting and reshoring. Foundry Lab is developing automated casting systems that control molten-metal viscosity to produce thin-walled, high-toughness aluminum components with limited specialized labor. The company aims to reduce long casting lead times, support on-demand production and rebuild distributed manufacturing capacity in the United States.
Timestamped Overview
00:00 – Introduction and overview of Foundry Lab’s metal-casting technology
01:30 – Digitizing an ancient manufacturing process and reducing dependence on specialized foundry knowledge
03:35 – Automated casting, viscosity control and production of complex thin-walled components
06:25 – Casting lead times, skilled-worker shortages and supply-chain constraints in aerospace and defense
09:15 – Mold design, process variability and how SpaceX, Tesla and other manufacturers developed internal casting capabilities
12:59 – Foundry Lab’s origins in New Zealand and the decision to establish operations in Texas
16:09 – Lessons from building a hardware-intensive startup and investing deeply in technical development
20:09 – Foundry Lab’s technical moat and its collaborative design-for-casting process with customers
23:17 – Entering the U.S. defense market, ITAR requirements and independent verification of material performance
27:03 – The relationship between software and hardware in rebuilding competitive Western manufacturing
31:15 – Industrial-base dependencies spanning mining, alloy production, insulation, vacuum equipment and other foundational suppliers
34:34 – Automation, machine vision, industrial power constraints and investment in manufacturing infrastructure
38:30 – Support from Peter Beck, Founders Fund and Foundry Lab’s New Zealand investors
43:31 – Scaling through a distributed casting-as-a-service network and potentially deployed defense foundries
49:04 – New-product manufacturing, on-demand sustainment, minimum orders of one and casting from the start
