Introduction
In recent years, the global aluminum casting market was estimated at USD 100.94 billion in 2024 and is expected to expand at a compound annual growth rate (CAGR) of 4.9% from 2025 to 2030. The Asia-Pacific region accounts for over 46% of the market revenue and continues to grow, driven by the concentration of manufacturing industries. Aluminum alloys offer over 30% weight reduction compared to steel while achieving high strength of 350 MPa or more, promoting their adoption in automobiles, industrial machinery, and building materials. Furthermore, their energy consumption during recycling is as low as 5% compared to primary production, and CO₂ emissions can be reduced by 95%, drawing attention from the perspective of decarbonization and a circular economy. This article will explain the diverse potential of aluminum casting and key points for procurement optimization through specific success stories in the fields of automotive parts, industrial machinery, and building materials.
Sources: Grand View Research Grand View Research, Precedence Research Precedence Research, Wikipedia: Aluminium recycling en.wikipedia.org
Success Stories of Aluminum Casting in Automotive Parts
Achieving Both Weight Reduction and High Strength
Aluminum castings using Al-Si or Al-Mg series alloys can achieve a 30-50% weight reduction compared to equivalent steel parts, significantly contributing to improved fuel efficiency and handling performance in automobiles. Additionally, some high-strength alloys, such as the 7005 series aluminum alloy, can reach a tensile strength of 350 MPa, ensuring sufficient rigidity and durability ScienceDirectWikipedia.
CO₂ Emission Reduction and Cost Benefits
Over their entire life cycle, aluminum parts have been reported to reduce CO₂ emissions by approximately 20% compared to steel products. When the effect of reduced fuel consumption during use is considered, an even greater reduction in environmental impact is possible LeClaire Manufacturing Co.. In addition, the high recycling rate of aluminum (95%) significantly lowers energy recovery costs compared to steel, suppressing material costs by about 10-15% Wikipedia.
Specific Case: Daiwa VN Steering Knuckle
– Vehicle Model: Lightweight SUV model for the European market – Benefits of Implementation: Reduced part weight by 40%, contributing to an annual CO₂ emission reduction of approximately 1,200 tons for the vehicle. – Patented “Steel Pin Insert Process”: By embedding high-tensile steel pins during casting, the fatigue strength of the joint is improved by 30% (ISO cycle tested) Elkamehr – Cost and Weight Comparison: For one lot (10,000 units), transportation costs were reduced by approximately 5% due to weight reduction compared to steel products, and material costs were also 3% lower.
Sources:
- Critical life cycle inventory for aluminum die casting: A lightweight …
- 7005 aluminium alloy (Wikipedia)
- Cast Aluminum At Its Best (LeClaire Manufacturing)
- Aluminium recycling (Wikipedia)
- Examples of aluminum casting for automobile parts (Daiwa Light Alloy VN)
Success Stories in Industrial Machinery Applications
Casting Processes for High Precision and Long Life
For industrial machinery parts, while high-pressure injection molding in die casting can generally achieve dimensional accuracy of ±0.02 to ±0.1 mm, sand casting has a tolerance of about ±0.5 to ±1 mm. Die casting combines high productivity with excellent surface quality and can accommodate parts with a minimum wall thickness of 1 mm or less 3DPCastingWikipedia. On the other hand, sand casting is strong in its application to complex shapes and small-lot production. By using wear-resistant aluminum alloys (such as A356), it can achieve high wear resistance with a tolerance within ±0.1 mm LinkedIn.
Accelerator Pedal for Caterpillar
Pentz Cast Solutions in the US developed an accelerator pedal for Caterpillar dump trucks using green sand casting with a steel insert embedded in an existing die-cast part. The improved part reduced field troubles by 50% compared to the conventional one, significantly enhancing its durability and reliability Pentz Cast Solutions.
Supply Chain Optimization through Overseas Procurement
Casting and machining costs at factories in Vietnam are said to be 20-30% lower compared to domestic manufacturing in Japan, and lead times can be shortened by about two weeks KPMGU.S. News. This simultaneously improves inventory turnover and reduces the risk of delivery delays.
Sources:
- Differences Between Aluminum Die Casting and Sand Casting 3DPCasting
- Die casting (Wikipedia) Wikipedia
- Cast In Diecasting with Steel Insert | Pentz Cast Case Studies Pentz Cast Solutions
- Cost of manufacturing operations around the globe (KPMG) KPMG
- These Countries Have the Cheapest Manufacturing Costs | U.S. News U.S. News
Success Stories in Building and Construction Applications
Decorative Exterior Parts via Permanent Mold Casting
Permanent mold casting, which uses the same mold repeatedly, can achieve both good surface quality and dimensional stability, making it suitable for decorative exterior parts of high-rise buildings. In a case study by Batesville Products, a large decorative component weighing 22 pounds (about 10 kg) was manufactured using permanent mold casting, followed by polishing and anodizing to ensure aesthetics and corrosion resistance. The complex rib structure was also stably formed, and after installation on a high-rise building in NYC, no discoloration or corrosion occurred, maintaining its appearance for over 20 years Batesville products, inc..
Free-Form Exterior Façade from ETH Zurich Research
The MAS Digital Fabrication team at ETH Zurich developed a free-form aluminum cast façade called “Deep Façade” using 3D-printed sand molds. They constructed a 3.5-meter-high wall by combining 26 custom panels. By using binder jetting technology to print the sand molds, they were able to cast complex shapes quickly and economically, which was traditionally difficult. A differential growth algorithm was introduced in the design to simultaneously optimize light transmission and structural constraints ResearchGateMaterialDistrict.
Recyclability and Environmental Compatibility
The energy required to recycle aluminum is only about 5% of that for primary production, and CO₂ emissions can be reduced by 95%, contributing to a lower environmental impact for building materials. The post-consumer recycling rate exceeds 95%, and it is expected to contribute to the circular use of construction waste and the acquisition of green building certifications (such as LEED) Batesville products, inc..
Sources:
- Aluminum Castings in Aesthetic Architecture (Batesville Products, Inc.)
- Bespoke Cast Facade (Aghaei Meibodi et al., ETH Zurich)
- A metal façade from a 3D printed mould (MaterialDistrict)
- Aluminium recycling (Wikipedia)
Data Box
| Indicator | Value | Source |
|---|---|---|
| Aluminum casting content per vehicle | 123 kg/vehicle (2023) | European Aluminium |
| CO₂ Reduction Rate | 15% (life cycle comparison) | Applied Energy |
| Accelerator Pedal Defect Rate Reduction | 50% (Caterpillar case) | Pentz Cast Solutions |
| Exterior Façade Service Life | 30+ years | Aghaei Meibodi et al., ETH Zurich |
| Recycling Rate | 95% | Wikipedia – Aluminium recycling |
Conclusion
In a wide range of fields including automotive, industrial machinery, and building materials, aluminum casting achieves over 30% weight reduction and high strength of 350 MPa or more compared to steel, leading to improved fuel efficiency and enhanced durability of machinery moving parts. Its high recyclability also contributes to reducing CO₂ emissions throughout its life cycle. In the future, with the spread of EVs and the advancement of smart factories, further demand expansion and higher functionality are expected. From a procurement perspective, multi-location sourcing, including Vietnam, allows for the diversification of currency fluctuation and geopolitical risks while achieving cost reductions of 20-30% compared to domestic production. Shortened lead times and improved inventory turnover also make it possible to strengthen the supply chain. Daiwa Aluminum Vietnam possesses the latest casting technology and a strict quality control system, with a strength in high-quality mass production supported by skilled local engineers. We support the provision of competitive products by responding swiftly to the diverse needs of our customers.
