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US Metal Casting Market

ID: MRFR/CnM/11363-HCR
111 Pages
Chitranshi Jaiswal
October 2025

US Metal Casting Market Research Report: By Metal (Cast Iron, Aluminum, Stainless Steel, Zinc, Magnesium), By Material Type (Cast Iron, Aluminum, Stainless Steel, Zinc, Magnesium), By Process (Sand Casting, Die Casting, Shell Mold Casting, Gravity Casting, Vacuum Casting), and By End-Use Industry (Automotive & Transportation, Building & Construction, Mining, Equipment & Machine, Consumer Goods) - Forecast to 2035.

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US Metal Casting Market Summary

As per Market Research Future analysis, the US metal casting market Size was estimated at 19.47 USD Billion in 2024. The US metal casting market is projected to grow from 20.33 USD Billion in 2025 to 31.28 USD Billion by 2035, exhibiting a compound annual growth rate (CAGR) of 4% during the forecast period 2025 - 2035

Key Market Trends & Highlights

The US metal casting market is experiencing a transformative shift driven by sustainability and technological advancements.

  • Sustainability initiatives are increasingly shaping the operational strategies within the metal casting industry.
  • Technological advancements are enhancing production efficiency and enabling innovative casting techniques.
  • Customization and prototyping are becoming essential to meet the diverse needs of clients across various sectors.
  • The rising demand in the automotive sector and infrastructure development initiatives are key drivers propelling market growth.

Market Size & Forecast

2024 Market Size 19.47 (USD Billion)
2035 Market Size 31.28 (USD Billion)
CAGR (2025 - 2035) 4.4%

Major Players

Alcoa (US), BASF (DE), Boeing (US), General Electric (US), Hitachi Metals (JP), Magna International (CA), Thyssenkrupp (DE), Toyota Tsusho (JP), Waupaca Foundry (US)

US Metal Casting Market Trends

The metal casting market is currently experiencing a dynamic phase characterized by evolving technologies and shifting consumer demands. Innovations in casting processes, such as additive manufacturing and advanced automation, are reshaping production capabilities. These advancements not only enhance efficiency but also improve the quality of cast products. Furthermore, the increasing emphasis on sustainability is prompting manufacturers to adopt eco-friendly practices, which may lead to a reduction in waste and energy consumption. As industries such as automotive and aerospace continue to grow, the demand for high-performance cast components is likely to rise, indicating a robust future for this sector. In addition, the metal casting market is witnessing a trend towards customization and rapid prototyping. Companies are increasingly focusing on tailored solutions to meet specific client requirements, which could enhance competitiveness. The integration of digital technologies, including artificial intelligence and machine learning, appears to facilitate better decision-making and operational efficiency. Overall, the landscape of the metal casting market is evolving, driven by technological advancements and changing market dynamics, suggesting a promising outlook for stakeholders in the coming years.

Sustainability Initiatives

The metal casting market is increasingly prioritizing sustainability, with manufacturers adopting practices aimed at reducing environmental impact. This trend includes the use of recycled materials and energy-efficient processes, which may lead to lower emissions and waste generation. As regulatory pressures intensify, companies are likely to invest in greener technologies to comply with environmental standards.

Technological Advancements

Innovations in technology are transforming the metal casting market, particularly through the adoption of automation and digitalization. Advanced manufacturing techniques, such as 3D printing and smart casting, are enhancing production efficiency and product quality. These developments may enable companies to respond more swiftly to market demands and improve overall competitiveness.

Customization and Prototyping

There is a growing trend towards customization within the metal casting market, as clients seek tailored solutions for their specific needs. Rapid prototyping technologies are facilitating this shift, allowing for quicker iterations and adjustments in design. This focus on bespoke products could enhance customer satisfaction and foster long-term relationships.

Market Segment Insights

By Material Type: Cast Iron (Largest) vs. Aluminum (Fastest-Growing)

In the US metal casting market, Cast Iron holds the largest market share due to its versatility and strength, commonly used in construction and automotive applications. Aluminum follows closely, gaining traction as a lightweight alternative, particularly in the aerospace and automotive sectors. Stainless Steel, Zinc, and Magnesium also play notable roles, but their shares remain smaller compared to these leading materials. Growth trends indicate a robust demand for Aluminum as the automotive and aerospace industries focus on reducing weight for fuel efficiency. Additionally, the versatility of Cast Iron in various applications ensures its sustained popularity. Emerging applications for Zinc and Magnesium in specialty industries also suggest gradual growth, yet they are still overshadowed by the more dominant materials.

Cast Iron (Dominant) vs. Aluminum (Emerging)

Cast Iron is a dominant material in the US metal casting market, favored for its strength and durability, making it ideal for heavy machinery and industrial equipment. Its ability to withstand high temperatures and mechanical stress adds to its appeal in various applications. On the other hand, Aluminum is an emerging material, increasingly popular due to its lightweight nature and corrosion resistance, driving its adoption in sectors such as automotive and aerospace. While Cast Iron remains preferred for traditional uses, the growing emphasis on sustainability and efficiency positions Aluminum to carve out significant market share. This contrast highlights the shifting dynamics within the market as manufacturers seek to balance performance with weight considerations.

By Process: Die Casting (Largest) vs. Sand Casting (Fastest-Growing)

In the US metal casting market, die casting holds the largest market share among the various casting processes. This segment is renowned for its efficiency and high production rates, making it the preferred choice for manufacturing complex metal components in various industries. Sand casting has been gaining traction due to its versatility and low production costs, contributing to its fast growth in the market. The growth trends in the market indicate a shift towards more automated and precision-oriented casting methods. As industries seek to improve efficiency and reduce waste, die casting remains dominant due to its high output capabilities. Meanwhile, sand casting is emerging as a favored process for smaller production runs, driven by advancements in technology that enhance its applicability and performance in producing intricate designs.

Die Casting (Dominant) vs. Sand Casting (Emerging)

Die casting is characterized by its ability to produce high volumes of complex parts with excellent surface finishes, making it ideal for automotive and electrical components. This process utilizes high pressure to force molten metal into molds, resulting in precise and uniform products that meet stringent quality standards. As a dominant player in the market, die casting benefits from economies of scale, enabling manufacturers to deliver cost-effective solutions for large production needs. On the other hand, sand casting is gaining traction as an emerging method due to its adaptability and lower initial costs, allowing for greater experimentation in design and material use. It is particularly favored for prototyping and small to medium batch production, making it a versatile option in the evolving casting landscape.

By End-Use Industry: Automotive & Transportation (Largest) vs. Building & Construction (Fastest-Growing)

In the US metal casting market, the market share distribution reveals that the Automotive & Transportation segment holds the largest proportion, reflecting its critical role in manufacturing vehicles and components. Following this, the Building & Construction sector showcases significant share, bolstered by rising infrastructural developments and demand for durable materials that metal casting provides. The Mining sector also contributes notably, though at a smaller scale compared to the leading segments. Growth trends in these segments are driven by advancements in technology and increasing demand for lightweight and high-performance materials. The Automotive & Transportation segment benefits from the ongoing push for electric vehicles, while the Building & Construction segment is experiencing a surge due to infrastructural investments and a shift towards sustainable building practices. Overall, these trends indicate a robust and evolving landscape in the US metal casting market.

Automotive & Transportation: Dominant vs. Building & Construction: Emerging

The Automotive & Transportation segment is characterized by its sheer volume and longstanding demand, firmly establishing itself as the dominant force in the US metal casting market. This sector drives innovation in casting technologies to reduce weight and improve fuel efficiency in vehicles. On the other hand, the Building & Construction segment is emerging rapidly, fueled by a construction boom and efforts to revitalize urban infrastructure. This segment focuses on casting durable, robust materials suitable for the varying demands of modern architecture. Together, they illustrate the dynamic interplay of established markets and emergent opportunities within the US metal casting landscape.

Get more detailed insights about US Metal Casting Market

Key Players and Competitive Insights

The metal casting market exhibits a dynamic competitive landscape characterized by innovation, strategic partnerships, and a focus on sustainability. Key players such as Alcoa (US), General Electric (US), and Waupaca Foundry (US) are actively shaping the market through their operational strategies. Alcoa (US) emphasizes technological advancements in aluminum casting, aiming to enhance efficiency and reduce environmental impact. General Electric (US) focuses on integrating advanced manufacturing techniques, particularly in aerospace applications, which positions it favorably in a niche market. Waupaca Foundry (US) is leveraging its extensive experience in iron casting to expand its footprint in the automotive sector, indicating a strategic alignment with industry demands.

The business tactics employed by these companies reflect a trend towards localizing manufacturing and optimizing supply chains to enhance responsiveness to market needs. The competitive structure of the market appears moderately fragmented, with several players vying for market share. However, the collective influence of major companies like Alcoa (US) and General Electric (US) suggests a potential for consolidation as they seek to leverage synergies and enhance operational efficiencies.

In September 2025, Alcoa (US) announced a partnership with a leading technology firm to develop a new aluminum alloy that promises to reduce weight while maintaining strength. This strategic move is likely to enhance Alcoa's competitive edge in the automotive and aerospace sectors, where lightweight materials are increasingly in demand. The collaboration underscores the importance of innovation in meeting evolving industry standards and customer expectations.

In October 2025, General Electric (US) unveiled a new digital platform aimed at optimizing the supply chain for its metal casting operations. This initiative is expected to streamline processes and improve production efficiency, thereby reducing costs. The strategic importance of this development lies in its potential to enhance GE's operational agility, allowing it to respond more effectively to fluctuations in demand and supply chain disruptions.

In August 2025, Waupaca Foundry (US) expanded its production capabilities by investing in advanced automation technologies. This investment is anticipated to increase production capacity and improve product quality, positioning Waupaca as a leader in the foundry sector. The strategic significance of this expansion is evident in its alignment with the growing trend towards automation in manufacturing, which is likely to enhance competitiveness in a rapidly evolving market.

As of November 2025, the competitive trends in the metal casting market are increasingly defined by digitalization, sustainability, and the integration of artificial intelligence. Strategic alliances are becoming more prevalent, as companies recognize the need to collaborate in order to innovate and meet regulatory requirements. The shift from price-based competition to a focus on technological advancement and supply chain reliability is evident, suggesting that future competitive differentiation will hinge on the ability to innovate and adapt to changing market dynamics.

Key Companies in the US Metal Casting Market include

Industry Developments

Recent developments in the US Metal Casting Market indicate a robust shift driven by technological advancements and sustainability initiatives. Companies like Steel Dynamics and Alcoa are increasingly investing in innovative processes to reduce carbon footprints while enhancing production efficiency.

Notably, Hollingsworth and Vose has made strides in advanced materials that cater to the growing demand for lightweight composite components, particularly in the aerospace and automotive sectors. In terms of mergers and acquisitions, Precision Castparts Corp announced the acquisition of Aerostructures, enhancing their foothold in the aerospace components market in July 2023.

By August 2023, Nucor's acquisition of a regional steel producer has reinforced its position in the architectural building markets, showing how consolidation is reshaping competitive dynamics. Market growth has also been catalyzed by increased infrastructure spending, with the US government allocating significant funds for roads and bridges, benefitting companies like Northwest Pipe Company and Americast.

The industry's valuation is projected to rise in the coming years, reflecting a rebound from previous challenges. Overall, the US Metal Casting Market is experiencing a period of dynamic growth, aligning with broader industrial trends toward modernization and environmental responsibility.

Future Outlook

US Metal Casting Market Future Outlook

The metal casting market is projected to grow at a 4.4% CAGR from 2024 to 2035, driven by advancements in technology, increasing demand in automotive, and sustainable practices.

New opportunities lie in:

  • Investment in automated casting technologies to enhance production efficiency.
  • Development of lightweight alloys for automotive applications to meet fuel efficiency standards.
  • Expansion into 3D printing for rapid prototyping and customized casting solutions.

By 2035, the metal casting market is expected to achieve robust growth, driven by innovation and evolving industry demands.

Market Segmentation

US Metal Casting Market Process Outlook

  • Sand Casting
  • Die Casting
  • Shell Mold Casting
  • Gravity Casting
  • Vacuum Casting

US Metal Casting Market Material Type Outlook

  • Cast Iron
  • Aluminum
  • Stainless Steel
  • Zinc
  • Magnesium

US Metal Casting Market End-Use Industry Outlook

  • Automotive & Transportation
  • Building & Construction
  • Mining
  • Equipment & Machine
  • Consumer Goods

Report Scope

MARKET SIZE 202419.47(USD Billion)
MARKET SIZE 202520.33(USD Billion)
MARKET SIZE 203531.28(USD Billion)
COMPOUND ANNUAL GROWTH RATE (CAGR)4.4% (2024 - 2035)
REPORT COVERAGERevenue Forecast, Competitive Landscape, Growth Factors, and Trends
BASE YEAR2024
Market Forecast Period2025 - 2035
Historical Data2019 - 2024
Market Forecast UnitsUSD Billion
Key Companies Profiled["Alcoa (US)", "BASF (DE)", "Boeing (US)", "General Electric (US)", "Hitachi Metals (JP)", "Magna International (CA)", "Thyssenkrupp (DE)", "Toyota Tsusho (JP)", "Waupaca Foundry (US)"]
Segments CoveredMaterial Type, Process, End-Use Industry
Key Market OpportunitiesAdoption of advanced manufacturing technologies enhances efficiency in the metal casting market.
Key Market DynamicsTechnological advancements drive efficiency and sustainability in metal casting processes, reshaping competitive dynamics.
Countries CoveredUS
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FAQs

What was the market size of the US Metal Casting Market by 2024?

In 2024, the US Metal Casting Market was valued at 19.78 billion USD.

What is the projected market size for the US Metal Casting Market by 2035?

The market is anticipated to reach a valuation of 32.58 billion USD by the year 2035.

What is the expected CAGR for the US Metal Casting Market from 2025 to 2035?

The expected compound annual growth rate (CAGR) for the market from 2025 to 2035 is 4.642%.

Which segment of the US Metal Casting Market held the largest market share in 2024?

The Aluminum segment led the market with a valuation of 6.5 billion USD in 2024.

What are the market values for the Cast Iron segment in 2024 and 2035?

The Cast Iron segment was valued at 5.0 billion USD in 2024 and is expected to grow to 8.25 billion USD by 2035.

Who are the major players in the US Metal Casting Market?

Key players in the market include Wabash National Corporation, Steel Dynamics, and Precision Castparts Corp.

What is the projected market size for the Stainless Steel segment by 2035?

The Stainless Steel segment is expected to reach a market size of 7.5 billion USD by 2035.

What is the projected market growth rate for the Zinc segment from 2024 to 2035?

The Zinc segment is projected to grow from a value of 2.5 billion USD in 2024 to 4.0 billion USD by 2035.

What trends are driving growth in the US Metal Casting Market?

The market is driven by increasing demand for lightweight materials and advancements in casting technology.

How does regionality impact the US Metal Casting Market?

Regional demand varies, with significant production concentrated in states known for manufacturing and industrial activities.

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