Why Choose VastMaterial for Aerospace Casting
At VastMaterial, we operate as a specialized aerospace casting manufacturer, built around the needs of US aerospace and defense programs.
Dedicated Aerospace and Defense Focus
We focus our foundry resources on flight‑critical and mission‑critical castings:
- Commercial and military engines
- Structural airframe castings and brackets
- Satellite, launch, and defense systems
- ITAR-controlled and classified components
We understand qualification gates, PPAP/AS9102, and configuration control, and we structure our programs around them.
End-to-End In‑House Casting and Finishing
We keep all critical aerospace foundry services under one roof to control cost, quality, and lead time:
- Process scope in-house: tooling, wax, molding, melting, heat treat, NDT, machining, and finishing
- Core processes: aerospace investment casting, aerospace sand casting, vacuum investment casting aerospace parts
- Program control: single point of accountability from RFQ through serial production
| Capacità | In‑House at VastMaterial |
|---|---|
| Tooling & 3D printed patterns | Yes |
| Melting & pouring | Yes |
| Trattamento termico | Yes |
| NDT & dimensional inspection | Yes |
| CNC machining & finishing | Yes |
Zero‑Defect Culture and Process Control
We run a zero‑defect, data‑driven quality system aligned with AS9100:
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Quando hai bisogno cURL Too many subrequests., cURL Too many subrequests. cURL Too many subrequests. using either air-melt or vacuum melt depending on the alloy and cleanliness required. Sand casting lets us hit larger envelope sizes and heavier pouring weights while still holding aerospace-grade quality and mechanical properties.
Precision shell casting for thin-wall geometries
For lightweight, thin-wall airframe bracket castings and complex housings, I use precision shell (ceramic shell) casting to keep wall thickness low without sacrificing consistency. This process is a sweet spot when you want near-net shape, reduced machining, and reliable repeatability on thin sections across production runs.
Aerospace Casting Materials Expertise
When it comes to aerospace casting, materials make or break the program. I’ve built our aerospace casting capabilities around the alloys U.S. aircraft, defense, and space customers actually use on flight-critical hardware.
Aluminum Aerospace Castings (A356, C355, A357, D357)
For structural airframe castings and lightweight housings, we run the core aerospace aluminum casting grades every day:
- A356 / C355 – Go-to alloys for structural airframe castings, brackets, and complex housings where weight and strength both matter.
- A357 / D357 – Higher strength options for landing gear components, load-path fittings, and performance-critical brackets.
We control chemistry and heat treatment tightly, and pair that with the right alloy selection using the same principles laid out in our guida sulle leghe da fonderia su tipi, proprietà e applicazioni.
Titanium Aerospace Castings (Ti‑6Al‑4V, Ti‑6‑4 ELI)
For parts that see extreme loads with strict weight limits, we specialize in titanium aerospace castings:
- Ti‑6Al‑4V – Widely used on engine mounts, structural brackets, and rotor system components.
- Ti‑6‑4 ELI – Cleaner, lower interstitial version for higher toughness and critical engine and defense parts.
These alloys are ideal when you need forged-level performance with the design freedom of precision aerospace castings.
Nickel-Based Superalloy Castings (Inconel 718, 625, Hastelloy X)
For hot-section aerospace engine castings and exhaust components, we pour cURL Too many subrequests. under vacuum:
- Inconel 718 – Standard for turbine discs, nozzle guide vanes, and structural engine parts.
- Inconel 625 – Great for corrosion-resistant exhaust and high-temp ducting.
- Hastelloy X – Strong performer for combustor and high-heat applications.
Our vacuum investment casting aerospace process is built around these superalloys so we can hit both fatigue and creep requirements.
Cobalt Alloy Turbine Casting Materials
For certain turbine and hot-section designs, we supply cobalt alloy turbine castings where thermal shock, oxidation resistance, and long-term stability are key. These are often used in liner segments, vanes, and legacy engine platforms where cobalt still outperforms nickel at the edge of the envelope.
High-Strength Steel and Stainless Aerospace Castings
When you need toughness, fatigue resistance, and reliable machining, we run a full range of aerospace steels:
- 15‑5PH / 17‑4PH – Workhorse precipitation-hardening stainless grades for hydraulic housings, gears, and structural aerospace castings.
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Helicopter Rotor and Drive System Castings
I also produce helicopter rotor cast components and drivetrain parts:
- Hubs, yokes, and gearbox-related castings
- High-integrity housings and brackets for dynamic systems
- Material options tuned for fatigue and vibration environments
All components are built with the process controls and inspection depth expected from a U.S.-focused aerospace casting company.
Quality Certifications and Aerospace Approvals
When you’re buying aerospace castings in the U.S., certifications and approvals aren’t a “nice to have” — they’re the minimum bar. I run our aerospace casting programs to that standard.
AS9100D & ISO 9001 Certified Aerospace Casting
We’re an AS9100D and ISO 9001–certified aerospace casting manufacturer, audited to the same quality framework used by top airframers and engine OEMs. That means:
- Documented, controlled processes for every aerospace casting job
- Risk-based planning for flight‑critical cast parts
- Corrective action and continuous improvement baked into production
If you’re building to aerospace or defense specs, our AS9100-focused aerospace operations give you the quality system your customers expect.
NADCAP Accredited Aerospace Processes
For special processes, we rely on NADCAP—not internal “trust us” standards. We maintain NADCAP accreditation on key aerospace foundry services such as:
- Heat treatment for aluminum, titanium, and nickel-based aerospace castings
- Nondestructive testing (NDT) for investment and sand cast parts
- Welding and other special processes where required
This lets U.S. primes and Tier 1s plug us into their approved supply base with minimal extra qualification.
OEM Approvals for Major Airframers and Engine Makers
We hold OEM casting approvals from major commercial and defense airframers and engine builders. That experience matters when you’re sourcing:
- Turbine engine cast components
- Structural airframe castings and bracket castings
- Hydraulic and actuation housings
If you’re a Tier supplier, we understand PPAP, source approval, and qualification testing requirements for these programs.
Full Material Traceability & AS9102 FAI
Every aerospace casting we pour is fully traceable, from melt lot to finished part:
- Heat and pour traceability linked to each serial number
- Controlled routers and digital inspection records
- AS9102 First Article Inspection (FAI) packages with full dimensional, material, and process data
Our internal testing and quality systems are aligned with aerospace expectations; you can see how we handle inspection and validation in our dedicated testing and quality control capabilities.
Inspection and Testing for Flight-Critical Aerospace Castings
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Scaling to full-rate aerospace production
When the program is ready to ramp, I scale up like a true aerospace casting manufacturer:
- Dedicated molds, gating, and process windows locked in with PPAP-style controls
- Capacity planning for long-term engine, airframe, or defense casting demand
- Stable pricing and delivery for full-rate production and spares
From first prototype to mature production, I run the same zero-defect mindset you expect from a U.S.-focused aerospace casting supplier.
Aerospace Casting Case Studies
Titanium impeller casting for turbofan engines
For a U.S. commercial turbofan OEM, we redesigned a machined titanium impeller as a near-net-shape titanium aerospace casting (Ti-6Al-4V).
Results we delivered:
- Cut part cost by over 25% by replacing hog-out from billet
- Hit tight balance and concentricity requirements right out of the mold
- Used vacuum investment casting to meet fatigue and FOD-resistance targets for flight‑critical service
Inconel 718 nozzle guide vane for military engines
A defense customer needed a durable cURL Too many subrequests. for a nozzle guide vane in a high-temp military engine core. Building on our superalloy experience and deep knowledge of Inconel alloy properties and grades, we:
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- Met stringent dimensional, grain size, and coating interface specs
- Passed full AS9102 first article and NADCAP special process audits on the first launch
Lightweight A357 structural bracket casting program
For a major airframer, we converted a multi-piece machined assembly into a single A357 aluminum aerospace casting for a structural airframe bracket.
What we achieved:
- Over 30% weight reduction with topology-optimized geometry
- Fewer fasteners and joints, improving reliability and assembly time
- Stable serial production with repeatable mechanical properties across lots, supporting long-term fleet programs in the U.S. market
Global Aerospace Casting Supply Chain & Logistics
When you source aerospace casting from us, you’re not just buying parts—you’re plugging into a global, defense-ready supply chain built for U.S. OEMs and tier suppliers.
Export Compliance & ITAR-Managed Programs
We treat export control as non-negotiable:
- ITAR and EAR compliant workflows with controlled access and documented procedures
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| Famiglia di leghe | cURL Too many subrequests. | cURL Too many subrequests. |
|---|---|---|
| cURL Too many subrequests. | A356, C355, A357, D357 | Airframe brackets, housings, structural parts |
| Titanium aerospace castings | Ti‑6Al‑4V, Ti‑6‑4 ELI | Impellers, engine mounts, high-load fittings |
| cURL Too many subrequests. | Inconel 718, 625, Hastelloy X | Turbine blades, vanes, hot-section parts |
| Cobalt alloy turbine castings | Co‑based high-temp alloys | Turbine vanes, hot wear parts |
| cURL Too many subrequests. | 15‑5PH, 17‑4PH, 300M | Actuation, landing gear, high-load fittings |
Need DFARS or ITAR-constrained melts? We flag that in the tables so sourcing stays compliant from day one.
Tolerances & Surface Finish for Aerospace Cast Components
We publish realistic, process-specific tolerance and surface finish bands so you don’t over- or under-spec your drawings.
Typical capability ranges (investment casting / vacuum investment casting aerospace):
| Feature Type | Typical Capability* |
|---|---|
| Linear dimensions | ±0.003–0.005 in/in (min ±0.003 in) |
| Hole location (as-cast) | ±0.005–0.010 in |
| Flatness / straightness | Process- and size-dependent |
| Surface finish (Ra) | 63–125 µin as-cast; finer with post-finishing |
Actual tolerances depend on alloy, size, and process (investment, vacuum, or aerospace sand casting). We lock these down with you during DFM and AS9102 planning.
Weight Reduction & Topology Optimization with Investment Casting
If you’re chasing weight targets on airframe bracket castings, satellite propulsion castings, or helicopter rotor components, investment casting is a strong play.
How we help cut weight without killing producibility:
- Usa topology-optimized geometries that exploit lost-wax design freedom
- Convert welded/machined assemblies to single-piece aerospace investment castings
- Push minimum wall thickness while staying within process capability and inspection limits
- Use higher-performance alloys (Ti‑6Al‑4V, Inconel 718) to shrink section sizes safely
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For the fastest and most accurate quote on aerospace investment casting, sand casting, or vacuum casting:
- Upload your 3D models (STEP, IGES, Parasolid) e 2D drawings (PDF)
- Include material specs (e.g., Ti‑6Al‑4V, Inconel 718, A356) and any aerospace standards you must meet
- Note your annual usage, target lead time, and program type (commercial, defense, space)
We’ll review manufacturability, flag risk areas, and come back with pricing, lead time, and recommended process for your flight‑critical cast parts. When you’re ready to move, you can start an RFQ directly through our contact and RFQ page.
Consult with Aerospace Casting Engineers
If you’re still refining your design or material choice, we’ll connect you with an aerospace casting engineer who deals with:
- Precision aerospace castings for engines, airframe brackets, and hydraulic housings
- Vacuum investment casting aerospace parts in nickel superalloys and titanium
- DFARS and ITAR-compliant defense casting supplier requirements
We’ll help you balance weight, cost, and reliability so your aerospace cast components are right the first time and ready for AS9102 first article inspection.
Recensioni
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