Metal Casting Design - Metalcasting Basics

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Metalcasting Basics

Metalcasting is a manufacturing process in which metal is melted and poured into molds where it solidifies into geometrically complex components. Metalcasting is unique among metal component forming processes for a variety of reasons.

First, the array of available metalcasting processes are capable of producing very simple to extremely complex components in almost any metal, ranging in weight from less than an ounce to several hundred tons. In addition, metalcasting processes are available that make it economical to produce a single prototype part, while others achieve their economies in creating millions of units.

In terms of value and volume, metalcasting ranks second only to sheet steel, which begins by casting steel slabs, in the metal producing industry. According to U.S. Department of Commerce statistics, metalcasting remains one of the ten largest industries when rated on a value-added basis. Annually, more than 2,000 metalcasters produce 13 to 15 million tons of castings valued at $35 to 40 billion (according to 2008 statistics).

The key to metalcasting design and purchasing comes down to understanding the metal-process marriage.

Spotlight On: Metalcasting Documentary

The documentary Spotlight On: Metalcasting was produced by AFS and aired nationally on PBS. The five-minute documentary provides an overview of metalcasting and the importance cast components play in our society.
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Census of World Casting Production

Below are the results of the annual Census of World Casting Production conducted by Metal Casting Design & Purchasing's sister publication MODERN CASTING over the last decade.

Casting Terms

Browse through our glossary for definitions of common metalcasting terms.
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U.S. Metalcasting Industry-At-A-Glance

The U.S. metalcasting industry is a global leader in the metalcasting industry and is the second-highest casting producing nation. The U.S. industry consists of 2,170 operating casting facilities (2008), of which approximately 700 produce ferrous castings and 1,400 produce nonferrous castings. Although the number of casting facilities in the U.S. has declined in the last 50 years, the productivity of the remaining facilities has increased. In 1991, there were 3,200 casting plants in the U.S., but more castings were produced in 2007 with 1,000 fewer metalcasters. Production capacity is only off by 4% compared to 1991.