Aluminium Casting Services Overview
You need aluminium casting that’s reliable, repeatable, and cost-effective—not trial-and-error. We run a dedicated aluminium casting foundry that supports US and global OEMs com custom aluminium casting from first prototype through long-term mass production. Our focus is simple: stable quality, clear communication, and on-time delivery for industrial buyers.
Custom Aluminium Casting for Industrial Buyers
We engineer and supply custom aluminium cast parts for demanding applications in automotive, e‑mobility, telecom, industrial equipment, electronics, and lighting. You get:
- Application-based alloy selection (A356, A380, ADC12, AlSi10Mg, AlSi9Cu3, EN AC-46000, EN AC-47100, and more)
- Design-for-manufacturing (DFM) feedback to hit weight, strength, cost, and tolerance targets
- Tooling, casting, CNC machining, and finishing under one roof for tight process control
- Suporte para US engineering teams with fast quoting and clear technical communication
Aluminium Casting: Prototypes to Mass Production
We handle the full lifecycle of your aluminium casting project:
- Rapid prototypes using soft tooling, sand casting, or 3D-printed patterns
- Bridge volumes while your production tooling is being built and validated
- High-volume production with automated aluminium die casting cells and robust process control
- Flexible MOQ options, so you’re not locked into quantities that don’t match your demand
Processes, Alloys, and Part Performance
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- cURL Too many subrequests. parts needing better surface finish than sand casting
- More stable dimensions and improved mechanical properties
- Housings, brackets, and industrial components
Sand Casting Aluminum
Sand casting aluminum works great when you need:
- Large castings or very low-volume runs
- Fast changes and lower tooling investment
- Prototypes, heavy industrial parts, and oversized housings
Investment Casting Aluminium (Lost-Wax)
Investment casting aluminium gives precision aluminium casting with extremely fine details:
- Thin walls, tight features, and complex internal shapes
- Small to medium parts where accuracy and appearance matter
You can see more about our approach to fundições de alumínio por investimento de alta precisão in our dedicated overview of precision custom aluminum investment castings.
Shell Mold Aluminium Casting
Shell mold aluminium casting bridges the gap between sand and permanent mold:
- Better surface finish and dimensional accuracy than standard sand
- Good option for small to medium parts where you want cleaner surfaces
- Stable quality with moderate tooling cost
No matter which aluminium alloy casting process you choose, we engineer it around your drawing, volume, and performance targets so you get the best balance of cost, quality, and lead time.
Common Aluminium Casting Alloys
Choosing the right aluminium casting alloy is the first big decision that impacts cost, strength, weight, and long-term reliability. Below is how we usually match alloys to real-world US applications.
A356 Aluminium Casting (High Strength & Ductility)
A356 (often heat treated to T6) is our go-to for parts that need both strength and toughness, not just good looks.
Melhor para:
- Structural brackets, suspension parts, control arms
- EV battery housings and safety-critical housings
- High-performance machinery components
Why we use it:
- High strength and ductility, especially in T6
- Great fatigue performance and weldability
- Good corrosion resistance for outdoor and road use
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- cURL Too many subrequests. ADC12, AlSi9Cu3/EN AC-46000 are better for oil, coolant, and hydraulic parts.
- Resistência à corrosão: A356 and AlSi10Mg perform well for outdoor and marine or road-salt environments.
- Cost & productivity: A380, ADC12, and EN AC-46000 are usually the most cost-efficient for large volumes.
If you share your part’s working environment (temperature, load, fluid contact, corrosion risk), we’ll recommend a short list of alloys and lock in the one that hits your performance and cost targets.
Industries Using Aluminium Casting Parts
Automotive & E‑Mobility Aluminium Casting
Fornecemos automotive aluminium castings e EV aluminium components built for high volume and tight tolerance, including:
- Motor housings, inverter and controller enclosures
- Transmission and powertrain aluminium cast parts
- Structural brackets, crossmembers, suspension mounts
- Battery housings and cooling plates for e‑mobility
With alloys like ADC12, A356, AlSi9Cu3, EN AC-46000, e EN AC-47100, we balance strength, weight reduction, and cost for North American OEMs and Tier 1 suppliers.
Aerospace & Defense Aluminium Casting
Para aerospace and defense aluminium casting, we focus on:
- Lightweight structural brackets and mounting hardware
- Housings for avionics and radar systems
- Heat-dissipating chassis and frames
We work to strict traceability and inspection standards (X‑ray, CMM, composition control) and draw on processes similar to our precision investment casting expertise shown in our serviços de fundição de precisão.
Telecom & 5G Aluminium Heat Sinks
Produzimos aluminium casting heat sinks and housings para:
- 5G base stations and remote radio units
- Telecom power supplies and network equipment
High pressure aluminium die casting gives thin walls, complex cooling fins, and accurate flatness cURL Too many subrequests.
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- cURL Too many subrequests. aluminium die casting for compact electronics, heat sinks, and auto parts
- Heavy-section sand casting aluminum parts for industrial and machinery components
Dimensional Tolerances for Aluminium Die Casting and Sand Casting
We run tight and realistic tolerances based on process and part geometry:
- High pressure aluminium die casting (HPDC):
- Up to ±0.002–0.004 in (±0.05–0.10 mm) on critical dimensions
- Excellent repeatability for large volume aluminium casting production
- Sand casting aluminium:
- Typical: ±0.01–0.02 in (±0.25–0.50 mm) depending on size
- Ideal for large, low-volume, and heavy-duty aluminium alloy casting
If you already have drawings, we can review your aluminium casting tolerance stack-up before tooling so you don’t fight quality issues later.
Annual Production Capacity for Aluminium Cast Parts
We’re built for both prototype runs and full production:
- Prototypes & small batches: de 10–50 pcs using flexible tooling options
- Mass production: hundreds of thousands of aluminium die casting parts per year
- Multi-shift operation on core cells to support automotive and industrial schedules
- Stable supply for automotive, telecom, and industrial OEMs in the US and abroad
In-House CNC Machining for Aluminium Castings
We machine our own CNC machined aluminium castings to hold tight fits and clean sealing surfaces:
- 3-axis and 4-axis CNC machining centers for complex precision aluminium casting
- Critical surfaces, threads, O-ring grooves, and datums machined in-house
- Consistent quality thanks to single-source control from casting to finish machining
For customers also using bronze or mixed-metal assemblies, we can coordinate with our own precision CNC machining services for bronze parts to keep everything aligned on tolerances.
Secondary Processing and Assembly
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DFM for Aluminium Casting Design Optimization
I start every aluminium casting project with DFM (Design for Manufacturability). We review your 3D models and prints to:
- Optimize wall thickness, draft, ribs, and fillets for aluminium die casting or sand casting
- Reduce porosity risk and improve metal flow
- Cut your tooling and part cost without hurting performance
Send us your CAD (STEP, X_T, IGES, or native SolidWorks) plus 2D drawings with key tolerances, and we’ll come back with clear DFM feedback before any tooling is cut.
Tooling Design and Mold Manufacturing
Once the design is locked, we move into tooling:
- 3D mold design for aluminium die casting, low pressure, gravity, or sand casting
- Cooling layout, overflow, and vent design to keep fill stable and reduce defects
- Tool steel selection and hardening for long tool life in high pressure die casting aluminium
You get mold design approval before manufacturing, so there are no surprises later.
Sampling and Aluminium Cast Prototype Validation
Before mass production, we always run a sample phase:
- First Article Samples from production tooling (or temporary tooling if you need fast prototypes)
- Full dimensional report on critical features
- Optional X-ray and leak testing on structural or sealing aluminium cast parts
We use this phase to dial in process parameters so you get stable quality from day one.
Mass Production of Aluminium Cast Parts
After you sign off samples, we move to volume:
- Automated or semi-automated cells for thin-wall aluminium die casting
- Stable process windows and control plans for automotive-grade repeatability
- Flexible batch sizes to cover both ongoing production and service parts
We can scale from a few hundred pieces to large-volume aluminium casting production for OEM programs.
Post-Processing, Inspection, and Packaging
Your aluminium cast parts don’t leave our floor until they’re finished and checked:
- CNC machining of critical faces, threads, and tight-tolerance features
- Deburring, cleaning, and surface finishing based on your spec
- 100% or sampling inspection with documented reports, then export-safe packaging tailored to your supply chain
For projects that combine aluminum with other metals (like wear or joint components), we can coordinate with specialty materials such as cobalt–chromium–molybdenum alloys from our high‑temperature alloy product line.
Logistics and Delivery Options
We ship aluminium castings across the U.S. every week and design logistics around your demand:
- FOB China with sea or air freight options
- Support for scheduled releases, safety stock, and JIT-style deliveries
- Custom labeling, barcodes, and packing lists to plug into your ERP
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If you’re also working with stainless or duplex steel parts in your system, we match our prototyping approach to interface precisely with components like your duplex stainless steel fasteners.
Die Casting Mold Design for Aluminium Parts
Good aluminum die casting starts with smart mold design. I focus on:
- Flow and filling – optimized gating and runners to avoid porosity and cold shuts
- Cooling layout – consistent cooling to manage distortion and keep tolerances tight
- Ejector layout – smooth ejection to protect part surfaces and thin walls
- Parting line and draft – simplified demolding and lower flash, especially for thin wall aluminium die casting and complex housings
You send us your 3D models (STEP, IGES, Parasolid) and 2D drawings, and we design aluminium casting tooling to hit your target tolerances and cycle times.
Tool Life and Maintenance for Aluminium Die Casting Molds
Tool life is a big cost driver in aluminium die casting, especially for U.S. buyers planning multi‑year programs.
Typical points I lock in:
- Material and hardness – premium tool steels and proper heat treatment for long life
- Expected tool life (rough guideline):
- Simple parts: up to 300,000–500,000+ shots
- Complex, thin-wall parts: tool life customized based on geometry and alloy
- Preventive maintenance
- Regular cleaning and polishing of cavities
- Checking and replacing wear inserts, pins, and slides
- Monitoring flash and dimensional drift before it becomes a quality problem
A clear maintenance plan keeps your parts consistent and avoids costly unplanned downtime.
Switching from Prototype to Mass Production in Aluminium Casting
I set up projects so you can move from prototype to production without starting over:
- Prototype stage
- 3D printed or CNC patterns
- Sand casting or gravity casting aluminium for quick feedback
- Early DFM (design for manufacturing) to keep future die casting in mind
- Pre-production / soft tooling
- Pilot molds or simplified die inserts
- Limited batches to fine-tune dimensions, gating, and cooling
- Mass production
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Quantidades Mínimas de Encomenda (MOQ)
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- Normalmente 3–5 semanas
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cURL Too many subrequests. casting capacity, CNC machining, and finishing around your US delivery schedule.
Aluminium Casting FAQ
Die Casting vs Gravity Casting
Principais diferenças:
| Item | Aluminium Die Casting (HPDC) | Gravity Die Casting |
|---|---|---|
| Filling | High pressure, very fast | Metal flows by gravity |
| Espessura da parede | Very thin walls possible | Medium wall thickness |
| Acabamento superficial | Very good, tight tolerance | Good, but less precise |
| Volume | Medium–very high volume | Low–medium volume |
| Custo | Higher tooling, lower part cost | Lower tooling, higher part cost |
Utilize fundição por pressão for thin‑wall, high-volume, precision parts.
Utilize gravity casting for simpler shapes, lower volume, and thicker walls.
Low Pressure vs High Pressure Aluminium Casting
When to choose which:
-
High pressure aluminium die casting (HPDC):
- Best for: thin walls, complex shapes, automotive & electronics.
- Pros: fast cycle, great surface, tight tolerance.
- Cons: more porosity, less ideal for heavy machining or pressure-tight parts.
-
Low pressure aluminium casting:
- Best for: wheels, housings, structural parts that need strength and low porosity.
- Pros: better metal quality, fewer gas defects, good for heat treatment.
- Cons: slower cycle, higher part cost than HPDC.
AlSi10Mg Aluminium Casting vs Additive Manufacturing
AlSi10Mg is common for 3D printed aluminum. If you’re replacing AM with casting:
- When casting makes sense:
- You’ve validated design with 3D printing.
- You now need lower part cost and higher volume.
- What we do:
- Convert your AM design to cast-friendly geometry.
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- Part weight and yield (gating/runner scrap)
- Tolerances & machining (CNC time)
- Acabamento de superfície (powder coat, anodize, plating)
- Annual and order volume
We quote transparently and show where design changes can cut cost.
File Formats & Drawing Requirements
To quote and build accurately, we need:
- 3D files (preferred):
- STEP (.step, .stp)
- IGES (.igs, .iges)
- Parasolid (.x_t) if available
- Desenhos 2D:
- PDF with full dimensions, GD&T, tolerances, critical surfaces.
- Extras (if available):
- Material specs and alloy (A380, ADC12, A356, etc.)
- Surface finish / coating spec.
- Annual volume and target price range.
Tolerances & Surface Finish Expectations
Typical ranges (we confirm per project):
| Processo | Linear Tolerance (normal) | Surface Finish (Ra) |
|---|---|---|
| HPDC aluminium | ±0.05–0.10 mm for small features | 1,6–3,2 μm |
| Gravity die casting | ±0.2–0.3 mm | 3,2–6,3 μm |
| cURL Too many subrequests. | ±0.5–1.0 mm | 6,3–12,5 μm |
Machined surfaces can reach Ra 0.8–1.6 μm easily.
Common Casting Defects & How We Prevent Them
Typical aluminium casting issues:
- Porosidade do gás
- Shrinkage porosity
- Cold shuts & misruns
- Warpage and distortion
- Surface blisters / inclusions
Our controls:
- Optimized runner, gate, and vent design.
- Controlled melt temperature and degassing.
- X-ray inspection and leak testing for pressure-tight parts.
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