Aluminum Investment Casting Services
Looking for lightweight, high‑precision aluminum parts without paying for heavy machining? Our aluminum investment casting services are built exactly for that. We use the lost‑wax (investment) casting process to deliver near net shape aluminum parts with tight tolerances, clean surfaces, and consistent properties—whether you need a few prototypes or full production.
What You Get With Our Aluminum Investment Casting
Mit unserem aluminum investment casting company, you get:
- Precision aluminum casting with tight, repeatable dimensions
- Thin wall aluminum castings and complex internal features
- Near net shape aluminum parts that cut machining time and scrap
- Heat treated aluminum castings (T5, T6, etc.) for higher strength
- Pressure‑tight aluminum castings for pumps, valves, and fluid systems
- Vollständige CNC-Bearbeitung, surface finishing, and assembly support in‑house
You send us a model or drawing, and we deliver ready‑to‑use custom aluminum investment castings to your spec.
Who Aluminum Investment Casting Is Really For
Unser investment casting aluminum process is a strong fit if you:
- Benötigen lightweight aluminum components with high strength‑to‑weight
- Have complex geometry that’s too difficult or costly to machine
- Want better surface finish and detail than sand casting
- Need consistent quality for aerospace, defense, medical, or industrial parts
- Care about reducing material waste and total part cost over the program life
We routinely support engineers in aerospace, automotive, defense, medical, electronics, and industrial equipment who need reliable, repeatable aluminum alloy investment casting.
How Our Aluminum Investment Casting Process Works at a Glance
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cURL Too many subrequests. precision aluminum casting a solid fit for:
- Housings, heat sinks, and thermal management parts
- Pressure‑tight aluminum castings for pumps, compressors, and hydraulic components
- Applications where you need both thermal control and leak‑free performance
With the right alloy and process control, we can hit tight porosity and pressure specs consistently.
Design flexibility for complex, thin‑wall parts
Lost wax aluminum casting shines when geometry gets tricky:
- Thin wall aluminum castings with stable, repeatable sections
- Intricate internal passages, undercuts, and branding details
- Near net shape aluminum parts that match 3D CAD closely
If you’re fighting design limits in machining or sand casting, complex aluminum castings via investment casting open up more options.
Cutting machining and material waste
Because we can cast to a Nahezu-Netzform, you:
- Remove less material in CNC machining
- Buy less raw stock and scrap fewer billets
- Shorten cycle times and reduce fixturing complexity
For many customers, moving to custom aluminum investment castings pays back quickly in reduced machining and material cost. If you also need die cast options, we back this up with dedicated aluminum casting alloy grades and services tailored for U.S. OEM production runs.
How Our Aluminum Investment Casting Process Works
Our aluminum investment casting process is built for precision, consistency, and repeatability, whether you need a few prototype parts or a full production run.
Wax Pattern & Tooling Setup
cURL Too many subrequests. high-precision wax patterns made from custom tooling or printed patterns for prototypes.
- Tight control of dimensions and shrink factors
- Optimized gating and riser design for sound aluminum castings
- Ideal für near net shape aluminum parts and complex geometries
Building the Ceramic Shell
Each wax pattern is dipped and coated to build a high-strength ceramic shell around it.
- Multiple layers for stable, pressure‑tight aluminum castings
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Wachsentfernung & Brennen der Schale
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Finish & Inspektion
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Most of our precision aluminum castings are poured in A356 (often heat treated to A356‑T6):
- Excellent strength‑to‑weight for lightweight structural parts
- Great fluidity for thin wall aluminum castings and complex features
- cURL Too many subrequests. for pressure‑tight aluminum castings and CNC machining
- Widely used in aerospace, automotive, and industrial aluminum components
For a deeper look at mechanical properties and uses, we rely on the same data you’ll find in this detailed overview of A356‑T6 aluminum alloy specifications and applications.
356 vs A356 vs C355 Aluminum Alloys
We cast all three depending on what your part needs:
- 356 – Good general‑purpose aluminum investment casting alloy, solid strength and castability.
- A356 – Cleaner, low‑impurity version of 356 with better strength, elongation, and pressure tightness. Our go‑to for high‑reliability parts.
- C355 – Higher copper content, higher strength, and elevated‑temperature performance, used when mechanical properties matter more than maximum corrosion resistance.
Custom Aluminum Alloy Options
When your project calls for something special, we can pour custom aluminum alloy investment castings, einschließlich:
- Alloys tuned for extra corrosion resistance
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- Specialty alloys for aerospace aluminum casting and defense
We match your print and spec to the right alloy using data from our in‑house casting alloy guide and resources similar to this casting alloy guide on types, properties, and selection.
Heat Treatment Options (T4, T5, T6)
To hit your strength and ductility targets, we offer full heat treatment on our aluminum castings:
- T4 – Solution heat treated and naturally aged; good toughness and formability
- T5 – Cooled from casting and artificially aged; stable dimensions, moderate strength
- T6 – Solution heat treated and artificially aged; maximale Festigkeit and hardness, ideal for high‑load parts
How to Pick the Right Aluminum Alloy
When we quote your aluminum investment casting, we’ll help you choose based on:
- Required strength, stiffness, and fatigue life
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Minimum Wall Thickness for Thin‑Wall Aluminum Castings
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Design for Aluminum Investment Casting
When Your Design Is a Good Fit for Aluminum Investment Casting
Your part is a strong match for aluminum investment casting when you need:
- Complex geometry: organic shapes, undercuts, internal passages, logos, and branding in one pour.
- Thin wall aluminum castings: walls down to ~0.06–0.08 in on small parts with consistent sections.
- Tight tolerances: precision aluminum casting for parts that must fit or seal without heavy rework.
- Lightweight strength: high strength‑to‑weight aluminum components that still handle real‑world loads.
If you’re not sure, send us your 3D model and we’ll give you a quick “yes/no” on aluminum investment casting feasibility.
How to Optimize Geometry for Aluminum Lost‑Wax Casting
To get the most out of lost wax aluminum casting, we usually recommend:
- Smooth transitions: use fillets and radii instead of sharp corners to improve flow and reduce stress.
- Consistent wall thickness: avoid big jumps in section thickness to control shrink and distortion.
- Proper draft where needed: 1–2° draft on features formed by tooling to keep wax patterns clean.
- Generous radii: avoid razor‑sharp edges that chip in wax or crack in the ceramic shell.
Our team has deep lost‑wax casting foundry experience and can quickly flag and fix geometry that causes casting issues.
Reducing Machining With Near Net Shape Aluminum Parts
One of the biggest wins with aluminum alloy investment casting is how much machining you can cut out:
- Cast bosses, pads, and flanges right to near net shape.
- Integrate brackets and features that would normally be welded or bolted on.
- Hold tight enough tolerances on non‑critical areas to skip secondary cuts.
We’ll help you decide what should be cast versus what should be machined so you hit your cost and lead‑time targets.
Common Design Mistakes and How We Avoid Them
Typical problems we see in investment casting aluminum designs:
- Too‑thin isolated features that break in wax or don’t fill with metal.
- Heavy mass areas with no transitions, causing porosity and shrink.
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cURL Too many subrequests. custom aluminum investment castings für:
- Electronics and sensor housings
- Pumps, manifolds, and valve bodies
- Compressor, gearbox, and motor components
If you’re focused on fluid control systems, our aluminum capabilities pair well with our broader valve castings manufacturing and custom OEM valve bodies experience. We also support corrosion‑resistant alloys for outdoor and plant environments.
Real Project Examples and Typical Use Cases
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- Thin-wall A356 electric motor housings that replaced multi‑piece weldments
- Complex aerospace brackets with integrated features that eliminated multiple machined parts
- Pressure‑tight pump and valve castings that cut weight versus stainless or bronze
If you’re developing lightweight aluminum components and want to combine performance with cost control, aluminum investment casting is usually one of the first processes we recommend.
Aluminum Investment Casting vs Other Processes
When you’re choosing how to make complex aluminum parts, the main question is: where does aluminum investment casting really beat die casting, sand casting, and permanent mold? Here’s the quick, practical breakdown.
Aluminum Investment Casting vs Die Casting
Druckguss is great for very high volumes, but it comes with trade-offs:
- Tooling cost: Die casting dies are expensive; investment casting tooling is usually lower cost, better for small to mid-volume runs.
- Teilekomplexität: Investment casting aluminum handles deeper undercuts, finer details, and thinner walls more easily.
- Mechanische Eigenschaften: Investment cast aluminum can use alloys (like A356) and heat treatments that are harder to run in die casting, giving better strength and fatigue performance.
- Surface & tolerances: Both are good, but precision aluminum investment casting often wins on fine features and near net shape for complex parts.
If you don’t need millions of parts a year, and you care about geometry freedom and performance, investment casting aluminum usually makes more sense.
Aluminum Investment Casting vs Sand Casting
Sandguss is flexible and cheap to start, but:
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Quality Control and Certifications for Aluminum Investment Casting
We run aluminum investment casting like a controlled process, not a guessing game. Every precision aluminum casting is checked, tested, and fully traceable so you know exactly what you’re getting and where it came from.
Dimensional & Visual Inspection
For every aluminum investment casting run, we verify the basics first:
- Full dimensional inspection against 2D/3D CAD
- CMM checks for tight‑tolerance features
- Visual inspection for surface defects, misruns, and porosity
- First Article Inspection (FAI) documentation when required
This keeps your near net shape aluminum parts on-size and consistent from lot to lot.
Metallurgical & Mechanical Testing
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- Tensile, yield, and elongation testing to verify mechanische Eigenschaften
- Hardness checks on heat treated aluminum castings (T5, T6, etc.)
Our lab procedures follow strict internal standards similar to those described in our Prüf- und Qualitätskontrollpraktiken.
Non‑Destructive Testing (NDT)
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- X‑ray inspection for internal shrink, porosity, and inclusions
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- NDT reports available with full traceability
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Process Control & Full Traceability
Every aluminum investment casting we ship can be traced back through:
- Melt lot, alloy batch, wax batch, shell ID, and heat treat record
- Controlled work instructions for each process step
- Recorded oven charts, pour logs, and inspection records
If there’s ever a question, we can track a part from raw material to final inspection in minutes.
Industry Standards & Certifications
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- 2D/3D files – STEP, IGES, or solid models + PDF prints with critical dimensions and tolerances
- Material – alloy and heat treat (e.g., A356-T6, 356-T6, C355)
- Annual volume + order quantity – prototype, bridge, or full production
- Oberflächenanforderungen – machining, anodizing, coating, or assembly
- Quality needs – NDT (X‑ray, dye penetrant), certs, PPAP, AS9100/ISO requirements
- Target price and timeline – helps us suggest the best process window
Typical Lead Times and Project Workflow
For aluminum investment casting projects, our flow is:
- DFM review & quote – usually within 2–5 business days
- Werkzeugbau & Wachsmodelle – 3–5 weeks depending on part complexity
- Sample / FAI castings – 2–3 weeks after tooling approval
- Production ramp‑up – scheduled releases or kanban to support your build plan
We plan capacity with U.S. customers in mind, so we’re upfront on lead times and realistic ship dates.
Pricing Factors for Aluminum Investment Casting Parts
Your aluminum casting cost mainly depends on:
- Part geometry – size, complexity, thin‑wall sections, and required tolerances
- Alloy and heat treat – A356 vs C355, T5 vs T6, etc.
- Volumen – prototype, low‑volume, or high‑volume production
- Secondary work – CNC machining, surface finishing, assembly, and testing
- Quality level – NDT, full traceability, and certification packages
If your program also needs stainless or alloy steel components, we can bundle them with our Edelstahl und Legierungstahl casting supply to tighten total project cost and logistics.
How We Support Prototypes and Production Programs
We’re set up to handle the full lifecycle of aluminum investment casting:
- Rapid prototypes – quick‑turn soft tooling or modified existing tooling
- Design tuning – DFM feedback to cut machining, improve yield, and stabilize quality
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We combine:
- Dimensional inspections with full layout on critical features
- Metallurgical and mechanical property checks
- Non‑destructive testing (X‑ray, dye penetrant, etc.) for mission‑critical parts
For customers needing other metals, we offer similar quality controls on titanium alloy cast and machined components as well as high‑performance copper‑based alloys like brass and bronze.
Q: Can you handle shipping and logistics in the U.S.?
Yes. We regularly ship aluminum investment castings across the United States, using your carriers or ours. We can:
- Pack to your standards (foam, dividers, labeled cartons, etc.)
- Support JIT releases and scheduled shipments
- Provide full traceability and documentation with each lot
Resources for Aluminum Investment Casting
We keep aluminum investment casting simple to spec and easy to source with practical, engineer-ready resources.
Design Guides & Datasheets
We provide clear design guides for aluminum investment casting that cover:
- Recommended wall thickness, draft, radii, and gating options
- Tolerance charts for precision aluminum casting and thin wall aluminum castings
- Material datasheets for A356 aluminum casting, 356 aluminum investment casting, and C355 aluminum alloy casting
These guides help you decide when aluminum lost wax casting is the right move versus other processes like CNC-Bearbeitung.
Alloy Data & Capability Charts
You get straightforward, downloadable specs that include:
- Mechanical properties for heat treated aluminum castings (T4, T5, T6)
- Comparison charts: 356 vs A356 vs C355 aluminum alloy investment casting
- Capability ranges for part size, weight, and tolerances for complex aluminum castings
We share real production ranges, not “lab-only” numbers, so you can design near net shape aluminum parts with confidence.
Process & Material Selection Articles
For engineers and buyers comparing options, we publish plain-English articles on:
- Investment casting aluminum vs die casting vs sand casting
- When to use lightweight aluminum components instead of steel or brass
- How to choose corrosion resistant aluminum alloys for aerospace aluminum casting, automotive aluminum cast components, and industrial parts
These resources are built around U.S. application needs and typical quoting workflows, so you can move from concept to RFQ without guessing.
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