What Is a Foundry? 

Understanding the Aluminum Casting Process with Alcast Company

An aluminum foundry is a specialized manufacturing facility where molten aluminum is transformed into durable, high-precision components. Foundries like Alcast Company use advanced casting processes—such as permanent mold casting, sand casting, and die casting—to create complex parts for industries including automotive, aerospace, energy, and heavy equipment.

With over 50 years of experience, Alcast Company stands as one of the most knowledgeable and innovative aluminum casting foundries in the United States. Our Peoria, Illinois facility combines proprietary technology with American-made quality, producing castings that meet exacting performance and durability standards.

Understanding Aluminum Casting

At the heart of every foundry is the process of transforming molten aluminum into functional parts. Different casting techniques offer distinct advantages, depending on the design and performance requirements.

Common Aluminum Casting Methods

• Sand Casting – Utilizes sand molds to form intricate shapes; ideal for prototypes and low-volume runs.
• Die Casting – Injects molten aluminum into steel molds under pressure for high-precision, high-volume production.
• Permanent Mold Casting – Employs reusable metal molds for superior dimensional accuracy and surface finish.

Alcast Company specializes in permanent mold aluminum casting, supported by our proprietary Mitchener Molding Process. This approach ensures exceptional consistency, minimal porosity, and repeatable results—critical for industries that depend on quality and performance.

When requesting a quote, providing detailed part information helps our engineering team determine the best casting process to match your production and budget needs.

The Role of Aluminum Foundries in Manufacturing

Foundries are the backbone of modern manufacturing. They turn raw aluminum into the essential parts that keep machines and infrastructure running.

At Alcast Company, our foundry produces a wide range of precision aluminum castings—from small, intricate parts to large, heavy-duty components weighing over 350 pounds. By controlling every stage of production in-house, including heat treating, machining, powder coating, and finishing, we ensure consistent quality and faster lead times.

Our flexibility allows us to accommodate production volumes from a few prototype parts to 250,000+ units annually, making Alcast a trusted partner for both custom projects and large-scale manufacturing programs.

Innovations in Modern Foundry Operations

As technology advances, so does the art of metal casting. Alcast Company continually invests in innovations that enhance precision, efficiency, and sustainability.

Leading-Edge Technologies in the Alcast Foundry

• Electro-Magnetic Casting Technology – Alcast is the only U.S. aluminum foundry using this advanced process for superior metal integrity.
• Smart Manufacturing & Process Control – Real-time monitoring ensures repeatable results and consistent quality.
• Simulation & Modeling Software – Predicts metal flow and solidification for optimized casting design and reduced waste.
• Automation & Robotics – Streamlines production and improves consistency across high-volume runs.

These innovations enable Alcast to deliver castings that meet demanding tolerances while reducing energy use and material waste.

Aluminum Casting Applications Across Industries

Aluminum’s combination of light weight, strength, and corrosion resistance makes it ideal for industries that depend on high performance and reliability.

Key Applications of Alcast Aluminum Castings

• Automotive & Transportation – Torque converter elements (turbines, impellers, stators), valve bodies, gear boxes, and drive train components.
• Agriculture & Off-Highway Equipment – Housings, manifolds, and engine components designed for durability and corrosion resistance.
• Mining & Industrial Machinery – Heavy-duty castings that perform in extreme environments.
• Energy & Power Systems – Lightweight yet robust parts that ensure long-term reliability.
• Aerospace & Defense – Precision aluminum components built to exact specifications for mission-critical performance.

Each casting produced at Alcast is engineered to provide strength, accuracy, and longevity, meeting the unique demands of our diverse customer base.

Environmental Responsibility in Foundry Operations

Sustainability plays an increasingly important role in the future of metal casting. At Alcast Company, environmental stewardship is integrated into every aspect of our operation.

We prioritize recycling, energy efficiency, and waste reduction throughout the production cycle. Our advanced filtration and cooling systems conserve resources, while continuous improvement initiatives help lower our carbon footprint. By manufacturing all products domestically in Peoria, Illinois, we reduce transportation emissions and maintain full accountability for environmental compliance.

Alcast’s commitment to responsible manufacturing supports both our customers’ sustainability goals and the broader effort to build a cleaner, more efficient industry.

Why Alcast Company Stands Apart

Not all foundries operate alike. What sets Alcast Company apart is our combination of tradition and technology—decades of craftsmanship backed by proprietary equipment and quality certifications.

Our ISO 9001:2015 and PED 2014 certifications (via TUV Rheinland of North America) reflect our dedication to precision, consistency, and safety. By building and maintaining our own casting and core machines, we reduce downtime and deliver competitive pricing—all while maintaining world-class quality.

For customers seeking a reliable aluminum foundry that delivers both performance and partnership, Alcast Company is the proven choice.

Partner with Alcast Company for Proven Foundry Expertise

A foundry is where molten metal becomes possibility—where engineering meets craftsmanship. At Alcast Company, that process defines who we are. With over 50 years of experience, proprietary technology, and full in-house capabilities, Alcast continues to lead the way in American aluminum casting. Whether you need precision components for automotive, mining, or industrial applications, our team is ready to deliver excellence from start to finish. Request a quote today and discover why Alcast Company is one of the most trusted names in aluminum foundry manufacturing.