Aluminum Castings

Aluminum casting is a widely used process that involves pouring or injecting molten aluminum into a mold to repetitively create complex and detailed parts. There are many types of casting processes. Each casting method uses different types of molds to produce the casting and involves either pressure or gravity to fill the mold with molten aluminum alloy.

For over 70 years, Le Sueur Incorporated has been the go-to supplier for quality aluminum castings. We are unique in a way that we offer multiple aluminum casting processes including Permanent Mold, Sand Casting and Die Casting. Offering all of these aluminum casting processes allows for an unbiased opinion when assisting our customers with selecting the best casting process, alloys and finishing processes to achieve a product’s specific requirements.

Early engagement with LSI's process dedicated engineering staff is essential to achieve a mutually successful project. These engineering professionals assist our customers in the product development process by incorporating the most advantageous tooling and aluminum casting practices. Together with our customer, a product design is evolved for the selected casting and manufacturing processes to produce the most cost efficient and robust part.

Considerations for Selecting the Best Aluminum Casting Process

There are several considerations in selecting the right aluminum casting process for your application. Review the considerations below to learn more or contact our experts to discuss any questions you have regarding which aluminum casting process is best for your application.

 

Casting Process

Surface
Finish

Casting
Tolerances

Tool Cost

Production
Cost

Production
Volume

Sand Casting

Low

Low

Low

High

Low

Die Casting

High

High

High

Low

High

Permanent Mold

Medium

Medium

Medium

Medium

Medium

Casting Process

Mechanical
Properties

Structural
Integrity

Pressure
Tightness

Internal
Soundness

Near Net
Shape

Sand Casting

Medium

High

Medium

Medium

Low

Die Casting

Medium

Medium

High*

Low

High

Permanent Mold

High

High

High

High

Medium

Casting Process

Ease of
Changes

Complexity
of Design

Tool Life**

Tool
Lead Time

Production
Lead Time

Sand Casting

High

Low

Low

Low

Low

Die Casting

Low

High

High

High

Medium

Permanent Mold

Medium

Medium

Medium

High

High

* Pressure tightness in die castings is improved by incorporating Squeeze Pin Technology.
** Tool Life is highly dependent upon type of tooling, casting geometry and surface finish requirements.

Contact Us to Discuss Your Aluminum Casting Project

Le Sueur Incorporated specializes in dimensionally complex, pressure tight aluminum castings and thermoplastic injection molded components. We offer complete in-house precision machining, finishing and assembly. Please contact us if you have a project to discuss!