Top 8 Aircraft and Aerospace Aluminum Casting Components Companies in Global 2025 | Global Growth Insights

Aircraft and aerospace aluminum casting components refer to specialized structural and functional parts manufactured through casting processes using aluminum and its alloys. These components are integral to engines, landing gears, fuselage supports, and wing assemblies. Their lightweight, corrosion-resistant, and high-strength properties make them essential for modern aircraft manufacturing, both in commercial aviation and defense applications. The U.S. has emerged as a dominant market, driven by high military spending and a thriving commercial aviation sector.

Aircraft and Aerospace Aluminum Casting Components Market size was valued at USD 1,192.78 million in 2023 and is projected to reach USD 1,303 million in 2024, eventually touching USD 2,418.89 million by 2032, exhibiting a CAGR of 9.24% during the forecast period [2024-2032].

USA Growing Aircraft and Aerospace Aluminum Casting Components Market

In 2025, the U.S. market for aircraft and aerospace aluminum casting components is projected to experience significant growth. According to industry indicators:

• The U.S. accounts for 37% of global aluminum casting demand in aerospace applications.
• The country houses over 400 aerospace foundries, with more than 70% focused on aluminum-based alloys.
• Military modernization programs have led to a 12% increase in procurement of cast components year-over-year.
• Boeing and Lockheed Martin collectively source aluminum castings from over 50 domestic suppliers.
• Aerospace exports from the U.S. exceeded $89 billion in finished parts in 2024, of which cast aluminum components contributed nearly 21%.

This strong base is reinforced by policies promoting reshoring, skilled labor availability, and automation-driven process control in foundries.

Regional Insights: Aircraft and Aerospace Aluminum Casting Components Market Share

North America – 42% Market Share

North America holds the largest share of the global market. Key drivers include:

• Widespread use in fighter jets like F-35, F-22, and commercial aircraft such as Boeing 737 and 787.
• U.S. Defense Department contracts with firms like Howmet Aerospace and PCC have spurred mass-scale aluminum casting investments.
• Canada’s aerospace manufacturing contributes 6% of North America’s regional production, with a focus on engine and turbine parts.
• Over 8 major R&D centers in the U.S. are dedicated to lightweight casting optimization for supersonic and unmanned aircraft.

Europe – 29% Market Share

Europe stands as the second-largest market with strong contributions from Germany, France, and the UK.

• Airbus’s manufacturing facilities in Toulouse and Hamburg use aluminum castings extensively in airframe components.
• Germany accounts for 35% of Europe’s production, led by firms like Zollern and CAM’s joint venture with local foundries.
• France’s aeronautics sector has seen a 17% increase in regional aluminum casting demand, supported by civil and defense programs.
• The UK’s investments in hybrid aircraft technology has boosted demand for precision-cast lightweight components.

Asia-Pacific – 21% Market Share

Asia-Pacific is growing rapidly, led by China, Japan, and India.

• China’s state-backed aviation program incorporates aluminum castings from CAM in regional and long-haul aircraft platforms.
• India’s HAL and ISRO use aluminum casting for both defense jets and space vehicle parts.
• Japan’s Mitsubishi and Kawasaki focus on engine components and precision systems, contributing to nearly 15% of APAC’s aluminum casting output.
• The region has over 70 foundries producing aviation-grade aluminum castings.

Global Growth Insights unveils the top List Global Aircraft and Aerospace Aluminum Casting Components Companies:

Company	Headquarters	Estimated CAGR (2021–2025)	2024 Revenue (USD)
Gaona	China	7.2%	$220 million
Denison Industries	USA	6.8%	$140 million
Impro Precision Industries	Hong Kong	8.1%	$530 million
Zollern	Germany	5.5%	$180 million
CAM (China Academy of Machinery Science and Technology)	China	9.3%	$310 million
Consolidated Precision Products (CPP)	USA	6.4%	$460 million
Precision Castparts Corp. (PCC)	USA	5.9%	$2.6 billion
Howmet Aerospace	USA	6.1%	$5.2 billion

Aircraft and Aerospace Aluminum Casting Components Regional Market Insights

Region	Top Application Area	Key Casting Method Used	Leading Country
Europe	Commercial aircraft airframe parts	Die Casting	Germany
Asia-Pacific	Jet engine components	Sand Casting	China
Latin America	Cargo aircraft fuselage sections	Permanent Mold Casting	Brazil
Middle East & Africa	Helicopter and UAV systems	Shell Mold Casting	UAE

Detailed Company Profiles and Strategic Developments (2023–2024)

1. Gaona

• Headquarters: China
• Specialization: Aerospace-grade precision sand and gravity die castings
• Component Focus: Turbine housing, engine brackets, cabin structural parts
• Recent Update: In 2024, Gaona expanded a new 35,000 sq. meter facility for dedicated aerospace-grade aluminum casting in Jiangsu province. The facility uses digital twin technology to simulate mold designs in real time.

2. Denison Industries

• Headquarters: United States
• Specialization: Military and defense aircraft castings (especially for transport and unmanned aerial vehicles)
• Component Focus: Landing gear housings, wing box castings, missile parts
• Recent Update: Partnered with the U.S. Department of Defense in 2023 to co-develop heat-resistant aluminum alloys, capable of withstanding thermal shock in hypersonic systems.

3. Impro Precision Industries

• Headquarters: Hong Kong
• Specialization: Multi-industry casting with aerospace division focusing on thin-wall aluminum investment casting
• Component Focus: Engine covers, turbine blades, fuel system brackets
• Recent Update: In 2024, Impro added five-axis CNC machining centers to support its integrated aluminum casting + finishing model. It also secured long-term supply agreements with major Japanese OEMs.

4. Zollern

• Headquarters: Germany
• Specialization: High-precision aerospace and space vehicle components using vacuum die casting
• Component Focus: Structural panels, thermal control parts for satellites
• Recent Update: In 2023, Zollern co-invested with Airbus in a zero-emission casting line in Ulm, achieving 20% energy savings per batch.

5. China Academy of Machinery Science and Technology (CAM)

• Headquarters: China
• Specialization: R&D and national projects related to aerospace manufacturing systems
• Component Focus: Rocket stage parts, aeroengine modules, heavy structural parts
• Recent Update: CAM's 2024 program integrated AI for real-time monitoring of porosity and microstructural integrity in large-scale aluminum castings.

6. Consolidated Precision Products (CPP)

• Headquarters: United States
• Specialization: Complex geometry castings and engineered aluminum alloys for jet engines
• Component Focus: Compressor casings, vane segments, exhaust structures
• Recent Update: CPP completed the acquisition of two specialty machining companies in 2023, enabling full vertical integration from casting to finish.

7. Precision Castparts Corp. (PCC)

• Headquarters: United States
• Specialization: Global leader in aerospace structural and rotating part castings
• Component Focus: Fan casings, combustor housings, structural joints
• Recent Update: In 2024, PCC implemented additive-assisted casting in its Oregon plant, combining 3D printed sand cores with traditional metal pouring. This reduced lead time by 30% on average.

8. Howmet Aerospace

• Headquarters: United States
• Specialization: Lightweight solutions, including investment casting and forged aluminum structures
• Component Focus: Fasteners, seat rails, engine mounts
• Recent Update: Howmet introduced a new line of corrosion-resistant cast aluminum alloys in 2023, aimed at extending part lifecycle in high-altitude flight environments.

Global Strategic Opportunities by Region

North America

• Focus Area: Advanced casting automation, military-grade components
• Opportunity: U.S. Air Force fleet modernization to require over 70,000 cast aluminum parts/year by 2027
• Trend: Increasing use of AI-based quality assurance and robotic pouring

Europe

• Focus Area: Sustainable production and lightweighting for green aviation
• Opportunity: EU’s “Clean Sky 2” program funding local casting innovation clusters
• Trend: Rising demand for hybrid aluminum-titanium cast composites

Asia-Pacific

• Focus Area: Expansion of regional jet programs and space vehicle structures
• Opportunity: China and India planning to launch over 40 indigenous aircraft platforms by 2030
• Trend: Shift from steel to aluminum casting in medium-thrust engines

Middle East & Africa

• Focus Area: MRO-based casting support and UAV infrastructure
• Opportunity: UAE's Al Ain aerospace park is setting up a dedicated aluminum alloy foundry
• Trend: Lightweight replacement of legacy components in military aircraft fleets

Latin America

• Focus Area: Regional transport and cargo fleet growth
• Opportunity: Brazil's Embraer-led alliances demanding higher local aluminum casting output
• Trend: Partnerships between domestic foundries and European OEMs

Technology and Process Innovations in Aluminum Casting for Aerospace

1. Vacuum-Assisted High Pressure Die Casting (HPDC)

• Used to produce complex airframe connectors and engine parts.
• In 2024, over 60% of aluminum aerospace components in North America used vacuum-assisted HPDC.
• Impro Precision and PCC adopted automated closed-loop vacuum control systems, resulting in defect reduction by 30%.

2. Additive Manufacturing Integration

• Hybrid casting + 3D printing is reshaping prototype and low-volume production.
• PCC's Oregon facility achieved 25% lead time reduction using 3D-printed molds.
• Zollern introduced topological optimization software for design-to-cast validation.

3. Real-Time X-ray & AI-Based Defect Detection

• CPP and CAM implemented AI-powered X-ray defect detection in 2023.
• These systems analyzed over 120 parts/hour, flagging internal cracks under 200 microns with 95% accuracy.
• Machine learning systems improved scrap reduction in China’s CAM casting units by 18% in 2024.

4. Lightweight Alloy Development

• Gaona and Howmet Aerospace jointly explored Scandium-aluminum alloys for extreme weight savings.
• The result: 7% lighter components with no compromise in structural strength.
• These alloys are being piloted in the new generation of regional jets and unmanned aerial systems.

Raw Material and Aerospace Supply Chain Trends

Aluminum Alloy Consumption Patterns

• In 2024, global aerospace aluminum alloy consumption exceeded 320,000 metric tons, with:
  • North America: 38%
  • Europe: 27%
  • Asia-Pacific: 26%
  • Rest of World: 9%
• Alloy grades 356, A356, and 7075 remain dominant, especially for structural and turbine components.

Sourcing Disruption and Localization

• 2023–2024 saw delays in bauxite supply from Guinea and alumina shipments from Australia.
• Howmet and Denison Industries shifted to regional aluminum recycling loops, increasing secondary aluminum use by 22%.
• India and China focused on rare-earth free alloy development to reduce dependency on imports.

Investment in Foundry Automation

• Over $1.4 billion invested in aerospace foundry upgrades globally in 2024.
• 74% of U.S.-based foundries upgraded to robotic pouring arms and modular furnace systems.
• Germany and Japan adopted closed-die, AI-monitored cooling chambers for faster cycle times.

Regulatory Landscape and Certifications (as of 2025)

Certification	Description	Region
AS9100D	Quality management standard for aerospace	Global
NADCAP (PRI)	Mandatory for cast components entering OEM supply chain	US/EU
EN 9100	European equivalent of AS9100	Europe
AMS Standards (SAE)	Detailed technical casting standards	North America
GB/T Aerospace Series	Chinese certification equivalent to EN/NADCAP	China

Key Certifications Required

2024 Developments

• 47% of new aerospace casting contracts globally now mandate both AS9100D and NADCAP certifications.
• In 2023, CPP and PCC expanded their in-house testing capabilities to meet evolving AMS2750 and AMS2175 updates.
• India’s BIS collaborated with ISO to launch new guidelines on aerospace aluminum casting uniformity standards.
• The EU launched its "Sustainable Aerospace Foundry Framework," requiring emissions transparency and ISO 14001 alignment by 2026.

Snapshot: USA’s Strategic Growth in Casting Sector

• U.S. leads with over 150 certified aerospace aluminum casting facilities.
• Investment from the Department of Defense for next-gen fighter program has led to:
  • 23 new aluminum R&D projects
  • 5 new partnerships between casting firms and aerospace OEMs
  • $600 million allocated for MRO facilities modernizing aluminum casting lines

Aircraft and Aerospace Aluminum Casting Components Market Forecast (2025–2033)

Year	North America (Units in Million)	Europe (Units in Million)	Asia-Pacific (Units in Million)
2028	8.4	6.0	5.3
2029	8.9	6.3	5.8
2030	9.3	6.7	6.3
2031	9.9	7.0	6.9
2032	10.5	7.4	7.6
2033	11.2	7.8	8.2

Investment and Acquisition Activities (2023–2025)

Precision Castparts Corp. (PCC)

• Investment: In 2024, PCC invested $300 million to expand its Portland casting facility.
• Focus: Automated pouring systems and real-time quality assurance.
• Impact: Increased output capacity by 22%, with a focus on turbine housing and rotating engine components.

Howmet Aerospace

• Acquisition: Acquired a niche aerospace casting firm in Connecticut (April 2023).
• Goal: Enhance design capabilities in single-piece aluminum castings for commercial aircraft.
• Outcome: Cut tooling lead times by 30%, improved access to narrow-body aircraft platforms.

China Academy of Machinery Science and Technology (CAM)

• Investment: Opened a $120 million AI-integrated casting center in 2023.
• Focus: Development of indigenous lightweight casting alloys for military aircraft.
• Significance: Aligned with China's 5-year aerospace self-reliance policy, supplying parts for COMAC and AVIC aircraft.

Impro Precision Industries

• Acquisition: Acquired an aerospace-specialized aluminum mold-making company in Taiwan in 2024.
• Purpose: Strengthen one-stop manufacturing model combining casting, machining, and inspection.
• Benefit: Opened access to 3 major Japanese aerospace OEMs.

Denison Industries

• Public-Private Partnership: Entered a co-funding agreement with the U.S. Air Force (2023) to scale aerospace aluminum alloy research.
• Funding Amount: $85 million
• Deliverables: 3 new alloy compositions tested for missile and UAV applications, passed thermal fatigue tests in Q1 2025.

New Product Developments and Strategic Launches

1. Gaona

• Product: Lightweight integrated structural panel for unmanned aircraft systems (UAS)
• Specs: 15% thinner wall section, weight reduction of 11% vs. prior generation
• Launch Year: 2024
• Application: Integrated into China's stealth UAV program

2. Howmet Aerospace

• Product: HX-1000 Series aluminum alloy casting for high-cycle fatigue environments
• Use Case: Jet engine vibration-dampening brackets
• Advancement: Maintains dimensional stability up to 580°C, introduced Q3 2024

3. Zollern

• Product: Thermally controlled satellite casing using a multi-core vacuum cast technique
• Innovation: Dual-material design with aluminum outer wall and ceramic-lined interior
• Use Case: ESA’s 2025 satellite series

4. CPP

• Launch: Self-healing aerospace aluminum composite launched in December 2024
• Feature: Microcapsules within the casting release repair agent under impact stress
• Market Reaction: Signed MoU with NASA for testing in low-orbit systems

5. PCC

• Innovation: Nano-structured aluminum foam cast components for eVTOL aircraft
• Highlight: 40% lighter than standard cast frame parts
• Launch Plan: Prototype phase completed in 2024, full-scale production slated for late 2025

Strategic Takeaways & Executive Summary for Stakeholders

1. North America Commands Innovation and Volume

• The U.S. remains the epicenter for innovation, certification leadership, and defense-linked demand.
• More than 42% of global production capacity resides in North America, with continued federal investment boosting capacity in PCC, Howmet, and Denison Industries.
• Vertical integration and automation are key themes in casting foundries, positioning the region for long-term competitiveness.

2. Europe Focuses on Sustainability and Lightweighting

• European aerospace manufacturers—particularly Airbus and its supplier base—are aggressively transitioning to eco-efficient casting practices.
• Firms like Zollern and CAM’s European partnerships are leading the way with closed-loop recycling and hybrid composite development.
• Regulatory tightening by the EU (e.g., ISO 14001 extensions) is driving R&D in emission-free casting lines.

3. Asia-Pacific Surges on the Back of Domestic Programs

• China, India, and Japan are investing in homegrown aerospace programs, creating regionally anchored demand pipelines.
• CAM, Gaona, and Impro are expanding alloy and process R&D to support both military and civilian aerospace needs.
• Asia is increasingly self-reliant, with localized aluminum processing chains and rising certification adoption (e.g., GB/T standards).

4. Materials and Technology are the Competitive Frontline

• Emerging alloy compositions (Scandium blends, nano-foamed aluminum) are enabling lighter and stronger cast parts.
• AI, robotics, and real-time quality analytics are no longer optional—they define the new efficiency baseline.
• 3D printed molds, digital twin-enabled design, and zero-defect initiatives are industry-standard in top-tier foundries.

5. Investment Momentum Is Shaping the Landscape

• Over $1.4 billion in aerospace-specific casting investment was tracked between 2023 and 2025.
• M&A activity is consolidating talent, design capabilities, and proprietary processes under larger umbrellas (e.g., Impro, Howmet).
• Governments are co-funding alloy development, MRO localization, and defense supply chain resilience—particularly in the U.S., China, and India.

What Stakeholders Should Prioritize in 2025 and Beyond

Stakeholder Type	Key Strategic Focus (2025–2027)
OEMs	Secure casting supply through long-term contracts; invest in joint design & testing with casting partners.
Foundries	Adopt AI-driven quality systems, pursue NADCAP & AS9100D aggressively, and diversify alloy portfolios.
Investors	Target regional champions in Asia and sustainability-driven innovation hubs in Europe for long-term ROI.
Government Bodies	Incentivize dual-use (civil & defense) component development and sustainable foundry practices.
R&D Institutes	Collaborate with industry to fast-track additive casting and foam-alloy hybrid components.