Precision aluminum investment castings with tight tolerances complex geometry aerospace-grade alloys and fast lead times for custom parts.
Precision Aluminum Investment Castings Gallery
Explore our collection of high-quality aluminum investment castings, showcasing intricate details and complex geometries achieved through the lost-wax casting process. From lightweight aerospace components to robust automotive parts, our castings balance precision and strength with superior surface finishes.
Aluminum Investment Castings — Delivering unmatched accuracy, complex shapes, and consistent performance for your most demanding projects.
Quick Specifications for Aluminum Investment Castings
| Specification | Details |
|---|---|
| Process | Lost-wax (investment) casting |
| Material Grades | A356, A357, AlSi10Mg, custom aluminum alloys |
| Part Weight | From a few grams up to 20 lbs (9 kg) |
| Wall Thickness | As thin as 0.04” (1 mm) |
| Dimensional Tolerances | ±0.005” (±0.13 mm) standard, tighter tolerances available |
| Surface Finish | 32–125 microinches Ra (smooth cast surfaces) |
| Max Size | Up to 24” (610 mm) in any dimension |
| Production Volume | Single prototypes to low and medium volume runs |
| Lead Time | 4–8 weeks depending on complexity and volume |
Our aluminum investment castings offer precision and consistency whether you need a single prototype or production quantities. We handle everything from thin-wall components to complex shapes with tight tolerances, making sure your parts meet exact specs and quality benchmarks.
Design Freedom
Investment casting lets you create complex, thin-wall shapes impossible with sand or die casting. This means fewer parts, lighter components, and faster assembly.
Strength-to-Weight Ratio
Using alloys like A356 and A357, investment castings deliver strong parts that keep weight low—perfect for aerospace and automotive uses.
Cost-Effectiveness
For short runs and low-volume production, investment casting cuts waste and machining, saving time and money compared to die casting or machining from solid blocks.
In short, aluminum investment castings offer the right balance of precision, strength, and design flexibility—helping U.S.-based companies stay competitive with quality parts that perform.
Common Aluminum Alloys We Pour
We use a range of aluminum alloys tailored to meet different strength, weight, and durability needs. Here’s a quick overview of the most popular alloys for aluminum investment castings, including their key mechanical properties and typical applications:
| Alloy | Tensile Strength (ksi) | Hardness (BHN) | Key Features | Typical Uses |
|---|---|---|---|---|
| A356 | 25-35 | 60-80 | Good corrosion resistance, weldable | Aerospace parts, automotive housings, pump bodies |
| A357 | 30-38 | 75-90 | Higher strength than A356, good fatigue resistance | Aircraft components, EV motor housings, medical devices |
| AlSi10Mg | 35-40 | 85-100 | Excellent strength-to-weight ratio, heat treatable | Precision aerospace parts, robotics, thin-wall castings |
| 319 | 30-40 | 70-100 | High thermal conductivity, good wear resistance | Engine parts, valve bodies, optical instrument parts |
These alloys let us cast complex geometry aluminum parts with thin walls while maintaining precision and structural integrity—perfect for demanding US markets in aerospace, automotive, and industrial sectors.
If you need custom aluminum investment cast parts with specific mechanical requirements, we can help you choose the right alloy to fit your application.
Industries & Applications
Aluminum investment castings fit a wide range of industries here in the U.S., thanks to their precision and strength-to-weight benefits. Here’s where they really shine:
- Aerospace & DefenseLightweight, high-strength parts for aircraft frames, engine components, and defense gear. Perfect for meeting strict safety and performance standards.
- Automotive & EVIdeal for electric vehicles and traditional cars alike. Aluminum castings reduce weight for better fuel efficiency and help with complex parts like housings and brackets.
- Medical & DentalPrecision castings are used in surgical tools, implants, and dental devices. The accuracy and consistency help meet strict sterilization and safety requirements.
- Robotics & AutomationAluminum investment castings enable durable, lightweight parts for robotic arms, precision sensors, and automation equipment where reliability is key.
- Pump & ValveCorrosion-resistant and sturdy components for fluid control systems. Aluminum castings help maintain tight tolerances needed for pumps, valves, and related parts.
- Optical & InstrumentationComplex, thin-wall castings are ideal for housings and fixtures in optical devices and scientific instruments, where precision really counts.
These industries rely on our aluminum investment casting expertise to deliver reliable, cost-effective parts that meet tight specs and help innovate faster.
Our Capabilities at vastmaterial
At vastmaterial, we handle every step of aluminum investment castings in-house to ensure quality and speed. Our services include:
- Pattern & Die Making: We create precise wax patterns and durable steel dies tailored for your production needs, whether prototypes or full runs.
- Shell Building & Pouring: Using advanced shell molding techniques, we guarantee consistent and defect-free castings with tight tolerances.
- Heat Treatment: We offer custom heat treatments to enhance mechanical properties like strength and hardness on alloys such as A356 and A357.
- Machining & Finishing: Our CNC machining and finishing processes provide parts ready for assembly or final use, maintaining excellent surface finishes and dimensional accuracy.
- Non-Destructive Testing (NDT): We perform rigorous inspections, including X-ray, ultrasonic, and visual testing, to catch flaws without damaging parts.
- Certifications & Reports: vastmaterial is proud to support AS9100 quality standards and provide necessary documentation like PPAP (Production Part Approval Process), FAI (First Article Inspection), and detailed CMM (Coordinate Measuring Machine) reports.
With this full range of capabilities, we deliver precise, reliable aluminum lost-wax castings that meet the high expectations of aerospace, automotive, and industrial customers nationwide.
Tooling & Cost Overview
For aluminum investment castings, we use wax patterns to create prototypes quickly and cost-effectively. This helps you test designs without a big upfront investment.
When you’re ready for production, we switch to durable steel tools. These tools handle high volumes and deliver consistent, precise castings.
Tooling lead times vary based on complexity:
- Wax patterns: 1–2 weeks
- Steel production tools: 4–8 weeks
We focus on keeping tooling costs competitive while ensuring quality, making aluminum investment castings a smart choice for both low-volume prototypes and full-scale production runs.
Design Guidelines for Aluminum Investment Castings
When designing aluminum investment castings, keeping a few basic guidelines in mind can save time and cost while improving part quality.
- Draft Angles: Use at least 1–3 degrees of draft on vertical surfaces. This helps with easy removal of the ceramic shell and reduces damage during casting.
- Fillets: Add fillets or rounded corners instead of sharp edges. This strengthens the casting, reduces stress concentrations, and improves metal flow.
- Ejector Pin Placements: Plan ejector pins in areas that won’t impact critical surfaces or dimensions. Proper placement avoids marks on visible or functional parts.
- Parting Lines: Position parting lines where they’re least noticeable and easiest to machine or finish. Keep them on flat or low-stress surfaces when possible.
Following these tips will help ensure smooth production and yield strong, precise aluminum lost-wax castings that meet your specifications.
Quality Assurance & Testing
We take quality seriously with every aluminum investment casting we deliver. Our process includes thorough chemical analysis to ensure the alloy meets exact specs. Mechanical testing checks strength, hardness, and durability so your parts perform as expected.
Before full production, we provide first article inspection (FAI) to verify dimensions and features match your designs. Every casting undergoes visual inspection to catch surface defects and confirm finish quality.
Dimensional inspections take place using precise tools like CMM (Coordinate Measuring Machines) to ensure tight tolerances and consistency. This thorough approach guarantees your aluminum castings meet or exceed industry standards, ready for use in aerospace, automotive, medical, and other critical applications.
Gallery / Case Studies: Real Success with Aluminum Investment Castings
Check out how we’ve helped U.S. businesses across industries with precision aluminum investment castings. From aerospace parts requiring tight tolerances to lightweight automotive components with complex geometry, our gallery showcases real projects that deliver quality and reliability.
What you’ll see:
- Photos of thin-wall aluminum castings with intricate designs
- Custom aluminum investment cast parts in aerospace and defense gear
- Medical and dental components crafted with A356 and A357 alloys
- Robotics and automation parts highlighting strength-to-weight benefits
- Examples of vacuum and rapid prototyping investment casting aluminum projects
Each case study includes a breakdown of challenges, solutions, and final outcomes, proving why customers trust us for their low-volume and high-volume casting needs. These success stories reflect our commitment to quality, fast turnaround, and meeting exact customer specs.
Explore our gallery to envision what we can build for your next aluminum investment casting project.
Comparison Table: Aluminum Investment Casting vs Sand Casting vs Die Casting vs CNC Machining
| Feature | Aluminum Investment Casting | Sand Casting | Die Casting | CNC Machining |
|---|---|---|---|---|
| Precision | High, great for complex shapes | Moderate, less detail | High, but limited shapes | Very high, tight tolerances |
| Surface Finish | Smooth, minimal post-processing | Rough, often needs finishing | Smooth, good finish | Very smooth, depends on tooling |
| Wall Thickness | Thin walls possible (0.03”-0.1”) | Typically thicker walls | Thin walls possible | No casting walls, solid stock |
| Design Complexity | Excellent, complex geometries | Limited by tooling and mold | Good, but less flexible | Unlimited, but time-consuming |
| Material Waste | Low, near net shape | High, lots of cleanup | Moderate | High, chips removed |
| Lead Time | Moderate (weeks) | Short to moderate | Short (days to weeks) | Varies, can be quick or slow |
| Production Volume | Small to medium | Medium to large | Large | Small to medium |
| Cost per Part | Moderate | Low | Low to moderate | High for large batches |
| Strength & Weight | Strong, lightweight parts | Strong but heavier | Strong but denser | Depends on stock/material |
| Ideal Use | Precision aerospace, medical parts | Large, simple shapes | High-volume automotive parts | Prototypes, low-volume custom |
Aluminum investment castings offer the best mix of detail, strength, and lightweight design, especially when you need complex shapes with tight tolerances. Sand casting is cost-effective for big, simple parts but doesn’t match that finesse. Die casting is fast for high volumes but limits design freedom. CNC machining shines in prototyping but can get pricey for bigger runs.
If you want precise, durable, and complex aluminum parts tailored to U.S. industry standards — investment casting is often the way to go.
Request for Quotation Form
Ready to get started with your aluminum investment castings? Use our easy Request for Quotation (RFQ) form below. It’s pre-filled with key details about aluminum investment casting to help speed up your quote. Just add your project specifics like part size, quantity, alloy choice, and any special requirements.
We’ll get back to you quickly with pricing, lead times, and options tailored to your needs. Whether you need precision aluminum investment castings for aerospace or custom aluminum investment cast parts for automotive, we’re here to make the process smooth and clear.
Fill out the form, and let’s bring your project to life.
FAQ: Aluminum Investment Castings
What is the minimum order quantity?
We accept low-volume aluminum investment casting orders starting as low as a few pieces, making it easy for prototyping and small batch runs.
Which aluminum alloys do you offer?
Common alloys include A356, A357, and AlSi10Mg. These provide great strength, corrosion resistance, and are popular for aerospace, automotive, and medical parts.
What casting methods do you use?
We primarily use lost-wax aluminum casting, including vacuum investment casting for tight tolerances and complex shapes. Rapid prototyping is available for quick turnaround.
Do you offer heat treatment services?
Yes, we provide heat treatment options like solution heat treatment and aging to enhance mechanical properties and improve strength-to-weight ratios.
If you have other questions or need custom specs, just reach out! We’re here to help with all your aluminum investment casting needs.
Related Processes & Materials
When considering aluminum investment castings, it’s helpful to know about related processes and materials that might fit your project needs:
- Stainless Steel Casting: Ideal for parts needing high corrosion resistance and strength, often used alongside aluminum castings in demanding environments.
- Aluminum Die Casting: Great for higher volume runs where fast production and lower per-piece costs matter, though it limits design complexity compared to investment casting.
- Vacuum Investment Casting: This process improves metal cleanliness and detail, perfect for critical aerospace or medical parts needing pristine quality.
- Rapid Investment Casting: Designed for quick prototyping or low-volume runs, it combines speed with the precision of traditional lost-wax aluminum casting.
Each process brings unique benefits, so we help pick the best fit based on your part’s design, volume, and performance needs.
Contact & Global Locations
Got questions about aluminum investment castings or need a custom quote? Get in touch with us directly. Our team is here to help you find the best solution for your parts, whether you’re in aerospace, automotive, or any other industry.
We serve customers across the United States, with easy access to our U.S.-based facilities. Plus, our global locations support fast delivery and local service worldwide.
Reach out to us:
- Call or email for quick answers
- Request a quote online anytime
- Visit one of our regional offices or manufacturing sites
No matter where you are, we’re ready to support your aluminum investment casting needs with precision, quality, and timely service.
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