Alucastor — Aluminum Casting Manufacturer in China
Alucastor is an aluminum casting manufacturer based in Dongguan, Guangdong, China. We produce cast and machined aluminum components for engineering teams who need a single supplier accountable for the whole part — from the first design-for-manufacturability review through tooling, melting, casting, heat treatment, CNC machining, surface finishing and final inspection.
Unlike trading companies that broker work to third-party foundries, Alucastor owns the process. Our 12,000 m² facility runs 28 casting machines and 36 CNC machines with an annual output of roughly 3,000 tonnes of aluminum. Tooling is designed and cut in-house, every heat is verified by spectrometer before pouring, and dimensional results are recorded on Zeiss coordinate measuring machines. When something needs to change on a casting, it changes in one building — not across three subcontractors and two time zones.
That structure is what makes us useful on difficult parts: thin-wall electronics housings, pressure-tight pump bodies, T6-treated suspension components and low-volume aerospace brackets where the tolerance stack matters more than the unit price. We work in English, German, Japanese, French and Spanish, and ship to customers across Europe, North America and Asia.
Our Aluminum Casting Services
Five production routes cover the full range from a one-off prototype to a 500,000-piece annual automotive programme. Each links to a dedicated page with tolerances, equipment and typical applications.
1. Gravity Die Casting
Aluminum poured under gravity into reusable H13 permanent molds. The slower fill and directional solidification give a denser, less porous structure than high pressure die casting, which means the parts are weldable and can be fully T6 heat treated. Best for medium-volume structural parts between 0.1 kg and 40 kg where mechanical properties matter.
2. Aluminum Sand Casting
Resin sand, green sand and 3D printed sand molds for large, complex or low-volume castings. Pattern costs are a fraction of permanent mold tooling and lead times are short, so sand casting is the practical route for prototypes, spare parts, pump and valve housings and castings above 40 kg. Internal passages that no die could form are straightforward here.
Aluminum Sand Casting Service →
3. Low Pressure Die Casting
Molten aluminum is pushed upward into the die at 0.2–0.7 bar, filling the cavity from below with almost no turbulence. The result is the lowest gas porosity of any of our processes — the reason it is specified for pressure-tight, safety-critical and X-ray-inspected parts such as wheels, EV battery housings and hydraulic manifolds. Yields are high because the un-solidified metal returns to the furnace.
Low Pressure Die Casting Service →
4. Precision CNC Machining
Thirty-six 3-, 4- and 5-axis machining centres and CNC turning centres finish our own castings and also run standalone machining from bar and plate. Critical features are held to ±0.02 mm, threads and sealing faces are machined in a single setup wherever the geometry allows, and surface finishing — anodising, powder coating, shot blasting, chromate — is arranged in-house.
Precision CNC Machining Service →
5. Rapid Prototyping
Two prototype routes depending on what you need to prove. CNC prototypes cut from solid 6061 or 7075 give a functional part in 5–7 days with no tooling. Casting prototypes made with 3D printed sand molds reproduce the real casting microstructure and wall behaviour in 10–15 days, so the prototype validates the production process rather than just the geometry.
Why Choose Alucastor
- One supplier, one accountability chain. Tooling, melting, casting, heat treatment, machining, finishing and inspection all happen at our own facility. There is no interface where a defect can be blamed on someone else.
- Engineering before tooling. Every enquiry gets a free DFM review covering wall thickness, draft, gating and machining datums. Fixing a casting on screen costs nothing; fixing it in hardened H13 costs weeks.
- Metallurgical control. Melting and degassing are monitored, every heat is checked on the spectrometer, and T5/T6 furnaces are on site — so mechanical properties are a specification we meet, not an outcome we hope for.
- Real inspection capability. Zeiss CMM, optical emission spectrometry, X-ray, dye penetrant and helium or air leak testing. Full dimensional and material reports ship with the parts.
- Honest process selection. If your part is better made by sand casting than by an expensive permanent mold, we will say so — even though the tooling revenue is lower.
- Multilingual, export-ready. Documentation, packing and logistics prepared for European, North American and Japanese customers, with quotations available in five languages.
Production Capacity at a Glance
Aluminum Alloys We Cast and Machine
Alloy selection drives castability, strength and cost more than any other decision on the part. These are the six material families we work with every day:
- Aluminum Alloy overview — how the casting and wrought families compare and when to use each.
- ADC12 Aluminum — the high-fluidity workhorse for thin-wall housings and covers.
- A380 Aluminum — balanced strength, castability and corrosion resistance for general structural parts.
- Aluminum Silicon Alloy — A356, AlSi7Mg and AlSi10Mg for T6-treatable, pressure-tight castings.
- 6061 Aluminum — weldable and highly machinable, used for CNC prototypes and machined assemblies.
- 7075 Aluminum — the highest-strength grade we machine, for aerospace and high-load fittings.
If you are unsure which grade suits your load case and environment, send the drawing and we will recommend one with the reasoning.
Industries We Supply
- Automotive — powertrain brackets, housings, structural and chassis castings under IATF 16949 discipline.
- Aerospace — low-volume, high-traceability brackets, housings and mounts with full material certification.
- Electronics — thin-wall heat sinks, RF and telecom enclosures where thermal path and EMI shielding matter.
- Industrial Equipment — pump bodies, valve housings, gearbox cases and machine frames.
- Robotics — lightweight arm segments, joint housings and end-effector mounts.
- New Energy — EV battery enclosures, inverter housings, motor cases and solar mounting hardware.
- Consumer Products — appliance and premium consumer housings where the finish is visible.
Quality Assurance and Inspection
Quality control at Alucastor starts before the first pour. The DFM review establishes datums and inspection points, the tooling is validated against a simulation of fill and solidification, and first articles are measured against the drawing on a Zeiss CMM before the programme is released to production.
In series production, every heat is verified by optical emission spectrometry and recorded against the batch. Castings destined for pressure or safety applications go through X-ray or dye penetrant inspection, and sealed components are helium or air leak tested to the specified pressure. Mechanical properties after T5 or T6 treatment are checked by tensile testing on cast-on bars.
Our quality management follows ISO 9001 and, for automotive programmes, IATF 16949. The plant operates an ISO 14001 environmental system, and RoHS and REACH material declarations are available for any alloy we supply. Certificates and dimensional reports travel with the shipment as standard, not on request.
From Drawing to Delivered Casting
- Enquiry and DFM review — you send a STEP or IGES model with a 2D drawing; we return manufacturability feedback and a process recommendation.
- Quotation — piece price, tooling cost and lead time, with the alternative process priced alongside if a cheaper route exists.
- Tooling design and manufacture — mold flow and solidification simulation, then H13 permanent mold or sand pattern manufacture in-house.
- First article sampling — sample castings with a full dimensional report and material certificate for your approval.
- Series production — casting, heat treatment, CNC machining, surface finishing and inspection, all under one roof.
- Packing and shipment — export packing, documentation and logistics prepared for your destination market.
Request an Aluminum Casting Quote
Tell us the alloy, the annual quantity, the tolerances that matter and the surface finish you need, and attach your model and drawing. Our engineering team reviews feasibility and returns a quotation with a DFM assessment — normally within one business day.
Use the quote form above, email us at hank@alucastor.com, or visit the contact page for full details. Further technical background on our processes is published on the Alucastor main site.