EV Die Casting Components Market Size, Share, Growth and Industry Analysis, By Types (High Pressure Die Casting (HPDC), Gravity Die Casting (GDC), Low Pressure Die Casting (LPDC), Others), By Applications (Two Wheeler, Passenger Vehicle, Commercial Vehicle), Regional Insights and Forecast to 2035

EV Die Casting Components Market Size

The Global EV Die Casting Components Market was valued at USD 19.09 billion in 2025 and is projected to reach USD 27.75 billion in 2026, eventually soaring to USD 802.61 billion by 2035. This remarkable expansion represents a strong CAGR of 45.34% during the forecast period from 2026 to 2035. The market growth is primarily driven by increasing electric vehicle adoption, lightweight material integration, and precision manufacturing. Around 60% of the total die-casting demand comes from high-pressure systems, with 40% from gravity and low-pressure processes combined. Over 70% of EV manufacturers are now shifting to large single-piece castings for chassis and body components.

The U.S. EV Die Casting Components Market shows consistent growth as automakers prioritize efficiency and scalability. The U.S. holds approximately 18% of the global market share, with over 35% of new EV manufacturing plants integrating automated die-casting technologies. Around 45% of North American EV producers now use lightweight aluminum alloys for key components, while 20% are adopting advanced magnesium blends for structural strength. Increased federal incentives and 25% higher domestic EV sales are strengthening the U.S. role in the global supply chain.

Key Findings

• Market Size: Valued at USD 19.09 billion in 2025, projected to touch USD 27.75 billion in 2026 and reach USD 802.61 billion by 2035 at a CAGR of 45.34%.
• Growth Drivers: Around 55% rise in EV adoption, 40% focus on lightweight components, and 30% expansion in casting automation across manufacturing hubs.
• Trends: Over 60% of manufacturers adopting high-pressure casting, 35% increasing magnesium usage, and 25% integrating vacuum-based casting systems.
• Key Players: Nemak, RYOBI, Guangdong Wencan Die Casting Co, Endurance, Handtmann & more.
• Regional Insights: Asia-Pacific holds 45% of the market driven by large-scale EV production, North America follows with 25%, Europe captures 20% with sustainable initiatives, and Middle East & Africa accounts for 10% through emerging EV infrastructure.
• Challenges: 30% production delays due to supply chain gaps, 20% cost escalation in alloys, and 15% shortage of skilled die-casting labor worldwide.
• Industry Impact: 40% improvement in manufacturing efficiency, 35% decline in energy waste, and 25% increase in product consistency across automotive casting operations.
• Recent Developments: 20% rise in large-scale casting projects, 15% boost in alloy R&D, and 25% increase in plant automation initiatives among top-tier players.

The EV Die Casting Components Market is transforming vehicle manufacturing by merging lightweight design with high structural integrity. Nearly 50% of upcoming EV platforms will rely on single-piece castings to reduce production time by 30%. Growing R&D in alloy innovation and advanced tooling continues to improve strength, efficiency, and durability across next-generation EV structures.

EV Die Casting Components Market Trends

The EV Die Casting Components Market is expanding steadily as electric vehicle manufacturing scales up worldwide. Around 75% of the die-cast materials used are aluminum-based, while magnesium and zinc collectively contribute about 25% of the total share. Asia-Pacific leads the market with approximately 50% share due to its strong EV production and supply chain network. Europe follows with nearly 25%, supported by advancements in lightweight vehicle design, and North America accounts for about 20% driven by increased EV adoption. Battery housings and motor housings collectively represent over 40% of total EV die-cast components, while pressure die-casting holds more than 55% of the production share, showing its dominance as the preferred manufacturing process. As automakers continue to focus on efficiency and cost reduction, the market is expected to see sustained double-digit growth in component output share across major EV-producing regions.

EV Die Casting Components Market Dynamics

OPPORTUNITY

Expansion into emerging materials

Manufacturers are increasingly adopting lightweight alloys to reduce vehicle mass and improve performance. Magnesium-based die-cast components have grown from under 10% to nearly 15% of the material mix in some EV categories. The use of innovative die-casting methods allows part count reduction by over 20%, enhancing manufacturing efficiency and durability across EV platforms. Additionally, nearly 30% of new EV designs now incorporate structural castings made from next-generation alloys for improved rigidity.

DRIVERS

Rising EV production volumes

Electric and hybrid vehicles now represent more than 30% of new vehicle launches in major markets. This growth drives the need for high-performance die-cast components. Over 40% of newly installed die-casting capacity worldwide is now dedicated to EV applications, with battery enclosures and motor housings accounting for the largest share. Additionally, about 25% of global automotive suppliers are expanding die-casting operations to meet the surge in electric vehicle demand.

RESTRAINTS

"Supply chain and raw material fluctuations"

Approximately 35% of die-casting producers face delays due to aluminum and magnesium supply shortages. Energy cost increases have driven production expenses up by more than 8% in the past period. Around 25% of companies report interruptions in alloy sourcing, slowing their ability to meet demand. These supply pressures continue to limit consistent production output, particularly in regions reliant on imported materials.

CHALLENGE

"Technological complexity of large-scale structural castings"

As automakers push for large, single-piece structural components, about 20% of production runs encounter defect-related rework due to precision and cooling challenges. Integrating new alloy compositions adds complexity, raising tooling and setup costs. Around 15% of smaller suppliers report delaying large casting projects because of the high cost of new equipment and limited access to advanced die-casting technologies.

Segmentation Analysis

The global EV Die Casting Components Market, valued at USD 19.09 billion in 2025, is projected to reach USD 27.75 billion in 2026 and soar to USD 802.61 billion by 2035, expanding at a CAGR of 45.34% during the forecast period. Segmentation by type reveals significant differences in material application, casting methods, and production efficiency across electric vehicle structures. Each casting process contributes uniquely to improving EV performance, reducing overall weight, and optimizing energy efficiency for next-generation models.

By Type

High Pressure Die Casting (HPDC)

High Pressure Die Casting dominates the market due to its ability to produce lightweight, precise, and durable parts used in EV battery enclosures, motor housings, and chassis components. HPDC accounts for more than 60% of total die-cast component production globally, driven by its suitability for mass manufacturing and superior dimensional accuracy. Around 70% of EV structural components currently use this process due to its strength-to-weight benefits and shorter cycle times.

High Pressure Die Casting (HPDC) held the largest share in the EV Die Casting Components Market, accounting for USD 16.65 billion in 2026, representing 60% of the total market. This segment is projected to grow at a CAGR of 46.1% from 2026 to 2035, fueled by rising EV production and the demand for complex, lightweight structures.

Gravity Die Casting (GDC)

Gravity Die Casting is primarily used for smaller, high-strength EV parts such as steering systems, suspension arms, and thermal housings. The process ensures better metal density and improved structural integrity. GDC contributes to nearly 20% of the overall die casting share and is favored in applications requiring superior fatigue resistance and thermal management, especially in premium electric vehicles.

Gravity Die Casting (GDC) accounted for USD 5.55 billion in 2026, representing 20% of the market. This segment is expected to grow at a CAGR of 42.7% during 2026–2035, supported by demand for high-performance EV components with extended durability and mechanical precision.

Low Pressure Die Casting (LPDC)

Low Pressure Die Casting is gaining momentum for its ability to create thin-walled aluminum parts suitable for EV battery enclosures and inverter housings. LPDC offers enhanced metallurgical quality with fewer porosity defects, making it ideal for components exposed to high thermal and mechanical stress. It contributes around 12% of the overall die casting demand, growing steadily as manufacturers shift toward premium EV applications.

Low Pressure Die Casting (LPDC) generated USD 3.33 billion in 2026, capturing 12% of the total market. This segment is projected to expand at a CAGR of 44.2% from 2026 to 2035, driven by the increasing adoption of advanced manufacturing techniques in EV structural production.

Others

The “Others” segment includes innovative hybrid casting techniques, such as vacuum die casting and squeeze casting, used in specialized EV applications where precision and reliability are paramount. These methods make up about 8% of the market and are crucial for niche EV segments like sports and performance electric vehicles that require custom alloy configurations and superior finish quality.

Other die casting methods collectively accounted for USD 2.22 billion in 2026, holding an 8% market share. This category is anticipated to grow at a CAGR of 41.5% between 2026 and 2035, driven by technological advancements in custom tooling and specialized lightweight alloys for next-generation EV systems.

By Application

Two Wheeler

The Two-Wheeler segment in the EV Die Casting Components Market is expanding as electric scooters and motorcycles adopt lightweight metal components to enhance range and energy efficiency. Approximately 25% of die-cast EV components are used in two-wheelers, particularly for motor casings, battery mounts, and frame supports. Manufacturers increasingly use aluminum alloys to reduce weight by nearly 20%, improving battery performance and durability. This growing shift toward urban mobility and micro-EVs continues to drive steady demand for compact die-cast parts globally.

Two Wheeler applications accounted for USD 6.94 billion in 2026, representing 25% of the total market share. This segment is expected to grow at a CAGR of 43.8% from 2026 to 2035, driven by increased adoption of electric bikes and scooters in emerging economies and rising focus on cost-efficient, lightweight mobility solutions.

Passenger Vehicle

Passenger Vehicles dominate the EV Die Casting Components Market, driven by the large-scale transition of conventional sedans, SUVs, and hatchbacks to electric models. This segment accounts for nearly 55% of total die-cast component demand, with major use in battery enclosures, chassis frames, and transmission housings. Automakers are integrating large single-piece castings that reduce component count by over 30%, improving production efficiency and vehicle rigidity. The growing focus on mid-range and premium EVs continues to boost demand for advanced die-cast components across key markets.

Passenger Vehicle applications held the largest share in the EV Die Casting Components Market, accounting for USD 15.26 billion in 2026, representing 55% of the total market. This segment is projected to grow at a CAGR of 46.2% from 2026 to 2035, supported by strong EV adoption rates, government incentives, and technological advancements in high-pressure die casting for passenger car structures.

Commercial Vehicle

The Commercial Vehicle segment is gaining momentum as electric vans, trucks, and buses transition toward large-scale production. This category accounts for about 20% of global EV die-cast component usage, with heavy emphasis on motor housings, structural brackets, and battery casing components. Demand is increasing from logistics and public transport sectors, with more than 35% of new fleet acquisitions expected to be electric by 2030. The segment is also witnessing a rise in adoption of high-strength alloys for durability under heavier load cycles.

Commercial Vehicle applications generated USD 5.55 billion in 2026, representing 20% of the total market share. This segment is forecasted to grow at a CAGR of 44.7% from 2026 to 2035, fueled by the electrification of logistics fleets, rising urban delivery networks, and fleet modernization initiatives in both developed and emerging economies.

EV Die Casting Components Market Regional Outlook

The Global EV Die Casting Components Market, valued at USD 19.09 billion in 2025, is projected to reach USD 27.75 billion in 2026 and further surge to USD 802.61 billion by 2035, expanding at a CAGR of 45.34% during the forecast period. Regional demand distribution highlights Asia-Pacific as the largest consumer and producer of EV die-cast components, followed by North America and Europe, while the Middle East & Africa region shows growing adoption of electric mobility solutions supported by government and industrial initiatives.

North America

North America represents a significant share of the EV Die Casting Components Market, driven by the rapid expansion of EV manufacturing and technological innovations in die-casting automation. The region accounts for about 25% of the global market, supported by strong demand from the U.S. and Canada for lightweight chassis and structural parts. Over 40% of North American automakers now use high-pressure die-casting systems for integrated EV platforms, enhancing production efficiency and cost competitiveness. The focus on electric pickup trucks and SUVs continues to accelerate regional growth in die-cast components.

North America held a substantial share in the EV Die Casting Components Market, accounting for USD 6.94 billion in 2026, representing 25% of the total market. This region is expected to grow at a CAGR of 44.8% from 2026 to 2035, driven by advancements in automotive manufacturing, EV adoption incentives, and a shift toward high-performance electric vehicles.

Europe

Europe accounts for around 20% of the EV Die Casting Components Market, led by strong automotive manufacturing bases in Germany, France, and the United Kingdom. The region benefits from strict emissions regulations and the shift to lightweight electric mobility solutions. Approximately 35% of European EV production utilizes advanced aluminum die-casting processes, reducing component weight by over 25%. Growing investment in gigafactories and EV component localization is further strengthening regional supply chain resilience and capacity expansion across major automakers.

Europe captured a notable share in the EV Die Casting Components Market, valued at USD 5.55 billion in 2026, representing 20% of the total market. This region is projected to grow at a CAGR of 45.2% from 2026 to 2035, supported by the transition to sustainable manufacturing and innovations in aluminum alloy casting for EV platforms.

Asia-Pacific

Asia-Pacific dominates the global EV Die Casting Components Market with an approximate 45% share, owing to high EV production volumes in China, Japan, and South Korea. Over 50% of global aluminum die-cast production capacity is concentrated in this region. China remains the largest contributor, accounting for nearly two-thirds of Asia-Pacific’s output, driven by extensive EV manufacturing infrastructure. Rapid industrialization and government support for local EV production continue to enhance demand for lightweight, precision-engineered die-cast components across both passenger and commercial electric vehicles.

Asia-Pacific held the dominant position in the EV Die Casting Components Market, accounting for USD 12.49 billion in 2026, representing 45% of the total market. This region is anticipated to grow at a CAGR of 46.5% from 2026 to 2035, propelled by strong manufacturing ecosystems, supportive government policies, and technological leadership in EV production.

Middle East & Africa

The Middle East & Africa region represents the emerging frontier for the EV Die Casting Components Market, holding about 10% of the global share. Increasing investments in renewable energy and electric transport infrastructure, especially in the UAE, South Africa, and Israel, are contributing to growth. Around 20% of the regional automotive component imports now involve EV-related die-cast parts. Local assembly projects and partnerships with global manufacturers are helping to establish a regional supply base for EV structural and drivetrain components.

Middle East & Africa accounted for USD 2.78 billion in 2026, representing 10% of the total market. This region is expected to grow at a CAGR of 43.1% from 2026 to 2035, driven by accelerating EV adoption, infrastructure development, and growing collaborations with international die-casting technology providers.

List of Key EV Die Casting Components Market Companies Profiled

Investment Analysis and Opportunities in EV Die Casting Components Market

The EV Die Casting Components Market is witnessing an influx of investment, with more than 35% of manufacturers expanding capacity to meet the growing demand for lightweight EV parts. Around 40% of global die-casting firms are adopting automation and robotic integration to enhance production efficiency. Nearly 30% of total investment spending is now allocated toward magnesium and aluminum alloy R&D to improve strength-to-weight ratios. Major automotive OEMs are forming partnerships with die-casting suppliers to localize production and cut logistics costs by 25%. The trend toward integrated chassis and mega-cast structures is also attracting over 20% of new venture funding, highlighting the sector’s long-term profitability potential. Additionally, more than 50% of global EV projects are expected to utilize die-cast frames by 2030, creating broad investment opportunities for precision casting facilities and tooling advancements.

New Products Development

Innovation in the EV Die Casting Components Market is accelerating as manufacturers focus on next-generation alloys and larger integrated castings. Over 45% of companies have introduced new die-cast designs for battery trays, motor housings, and inverter enclosures optimized for lightweight performance. Around 30% of newly developed EV platforms now feature single-piece rear or front body castings to reduce part count and assembly time by nearly 25%. Magnesium-based casting components are gaining traction, increasing their adoption rate by 12% year-on-year. Furthermore, about 40% of key market players are implementing vacuum die-casting and squeeze casting technologies to enhance surface integrity and structural consistency. Collaborative R&D between automakers and casting manufacturers is driving breakthroughs in thermal management and corrosion-resistant coatings, significantly boosting overall product life and system reliability in electric mobility applications.

Recent Developments

• Nemak’s Expansion in Structural Casting: In 2025, Nemak expanded its structural die-casting capacity by 20% across North America to meet rising demand for EV components. The company introduced advanced multi-cavity die systems that improve production efficiency by 15%, enabling faster turnaround and higher precision in aluminum alloy parts for electric vehicles.
• RYOBI Launches Next-Gen Casting Technology: RYOBI unveiled a new high-pressure die-casting line capable of reducing material waste by 18% while increasing energy efficiency by nearly 25%. The system focuses on lightweight aluminum structures, supporting the growing adoption of large-format EV body parts with improved durability and dimensional accuracy.
• Guangdong Wencan Introduces Large-Scale EV Casting Facility: Guangdong Wencan Die Casting Co established a new facility in 2025 with an annual capacity increase of 30%, focusing on producing single-piece EV rear frames. The plant integrates fully automated casting machines that enhance output consistency and reduce defect rates by over 10% compared to conventional methods.
• Endurance Expands EV Component Production: Endurance Technologies expanded its die-casting unit in India, increasing EV component production by 22%. The company invested in hybrid vacuum-pressure casting systems to improve the quality of thin-walled structural components, catering to both domestic and export EV markets.
• Hitachi Metals Develops Advanced Magnesium Alloys: Hitachi Metals launched a new magnesium alloy with 30% greater heat resistance and 12% improved weight reduction over standard aluminum castings. This innovation aims to enhance the performance of EV battery housings and inverter systems while reducing overall material consumption in large-scale automotive casting operations.

Report Coverage

The EV Die Casting Components Market report provides an extensive analysis of the global industry landscape, highlighting key trends, growth drivers, and future opportunities across major regions. The study covers over 18 leading manufacturers and evaluates their strategic developments, technological advancements, and product innovation initiatives. Around 60% of the report focuses on market segmentation by type and application, offering a detailed breakdown of high-pressure, gravity, and low-pressure die-casting methods. Approximately 40% of the coverage analyzes regional dynamics, outlining how Asia-Pacific, North America, Europe, and the Middle East & Africa collectively contribute 100% of the global share. The report includes a comprehensive assessment of supply chain structures, cost optimization techniques, and production efficiency metrics that account for nearly 50% of overall market performance. Furthermore, it tracks over 25% growth in new material adoption, emphasizing the shift toward aluminum and magnesium-based alloys. The coverage also evaluates investment patterns, where nearly 35% of capital allocation targets automation, tooling enhancement, and large-scale casting technologies. With 70% of the industry’s innovations centered on lightweight structures and sustainability goals, the report ensures a data-driven perspective that enables stakeholders to identify high-growth opportunities and competitive strategies in the rapidly expanding EV die-casting components ecosystem.