Publish Date: September 2026
Updated Tariff & Recession Risk Analysis and Forecasts
The Aluminum Casting Operations Market Report covers the $2.7 billion industry which produces lightweight components primarily for transportation, machinery, and consumer product applications through various casting technologies. Competitive structure features both high-volume automotive suppliers and specialized foundries addressing premium market segments. Market requirements increasingly emphasize dimensional precision, surface quality, mechanical properties, and increasingly complex thin-wall geometries supporting lightweighting objectives. Manufacturers face challenges balancing specialized melting and molding technologies, alloy optimization, porosity control, and tariff implications affecting both aluminum inputs and international market access. Successful companies establish advantages through advanced casting technologies enabling complex designs, specialized alloy development optimizing properties, comprehensive testing ensuring quality, and increasingly closed-loop recycling addressing sustainability concerns in a sector where both technical capabilities and quality consistency determine competitive positioning across diverse aluminum casting applications.
Aluminum Casting Operations Industry Definition
Aluminum Casting Operations produce lightweight metal components through various casting methods including die casting, permanent mold, and sand casting techniques. Companies melt aluminum alloys, cast them into molds, and perform finishing operations to create components with optimal combinations of weight, strength, and cost-effectiveness. These businesses serve transportation, construction, and consumer product markets with components offering significant weight reduction compared to steel alternatives. The industry continues advancing casting technologies that enhance aluminum’s advantages in applications requiring weight reduction, complex geometries, and moderate strength, with increasing focus on high-integrity casting methods that enable structural applications previously dominated by steel components.
NAICS Code: 331524
Number of Companies: 320
Number of Plants / Facilities: 329
Industry Employees: 13,930
Market Size: $2.7 billion
TARIFF IMPACT (Summer 2025 – Download Report for Updated Analysis)
This report has in-depth analysis on the recent US tariff changes on material costs, quantifying import dependencies, tariff exposure rates, and key source countries for the aluminum casting operations sector.
Estimated Tariff Cost: $50 million
Relative Tariff Impact: MODERATE
Aluminum Casting Operations Report Format
The 2026 U.S. Aluminum Casting Operations Market Report is 63 pages of deep insights into the trends, dynamics, and forecasts shaping the industry. Professionals leverage this market report to develop a deep understanding of the market for business strategy, planning, forecasting, benchmarking, industry analysis, valuations, identifying organizational inefficiencies, financial analysis, and more.
With more than one hundred industry analyses and data sets covering trends from 2017 to 2025 and forecasts for 2026 and 2030, this report is one of the comprehensive assessments of the industry. The report includes market size & growth, in-depth OPEX analysis on 26 categories, dozens of financial metrics, extensive forecasts, inventory statistics, detailed breakdown of 31 balance sheet items, company segmentation analysis, top 50 companies analysis, material costs benchmarks, profitability analysis, state metrics analysis, plant productivity benchmarks, employee role analysis, inflation trend benchmarks, compensation analysis, in-depth productivity analysis, and numerous other data sets.
Below are a few page images from the report and check out the table of contents for a complete overview.
Report Table of Contents
Evaluate the table of contents to appreciate why thousands of professionals, bankers, consultants, accountants, and other executives rely on Kentley Insights for data-rich industry insights.
The sources for the report data include federal and private surveys completed by the majority of companies in the sector covering extensive financial and operational topics for the aluminum casting operations industry. The forecasts in the report are modeled by our research analysts using the latest economic forecasts, industry analysis, and historical trends.
1-2 – Market Report Overview & Contents
3 – Market Overview
– Data Sources & Methodology
– Sector Definition & Examples
– Market Commentary
4 – Report Synopsis – Revenue & Growth
5 – Report Synopsis – Costs & Profitability
SECTION ONE
REVENUE & GROWTH
7 – Market Size Details
– Industry Revenues, Companies, & Facilities
– Analysis 2017-2025
– 2026 & 2030 Forecasts
8 – Growth Benchmarks
– Sales per Company and Plant
– Analysis 2017-2025
– 2026 & 2030 Forecasts
9 – Product Lines Revenue
10 – BCG Matrix – Income vs. Revenue Growth
11 – Total Industry Sales by Month & Year (2021-2025)
12 – Inventory Value by Month & Year (2021-2025)
13 – Months of Inventory (2021-2025)
14 – Sector Revenue by Segments
– Business Concentration, Size, & Structure
15 – Market Size by State
– Market Size and Rankings
16 – Market Size as a % of State GDP
17 – Sales as a % of State Manufacturing
18 – Market Segmentation by Business Size
19 – Market Segmentation by Business Size
– Business Size Segments – 1-4, 5-9, 10-20, 21-50, 51-100, 101-250, & 250+ employees
– Companies, Facilities, Sales, Employees & Payroll
20 – Segmentation by Concentration (Top 50 Companies)
– Concentration Segments – Top 4, 5-8, 9-20, & 21-50 companies
– Companies, Facilities, Sales, Employees & Payroll
21 – Market Share of Top 50 Companies
22 – Subsector Market Share of Top 50 Companies
23 – Segmentation by Business Structure
– Business Structure Segments – C-Corporations, S-Corporations, Partnerships, & Sole Proprietorships
– Companies, Facilities, Sales, Employees & Payroll
24 – Revenue per Company by State
25 – Revenue per Company by Segments
26 – Revenue per Facility by State
27 – Revenue per Facility by Segment
28 – Subsector Market Size & Growth
29 – Subsector Sales per Company & Plant
30 – 5-Year Consolidation Analysis
31 – Employment Consolidation Analysis
32 – Subsector Consolidation Analysis
– Number of Companies & Facilities
33 – Subsector Consolidation Analysis
– Facilities & Employees per Company
COST, CAPITAL & FINANCIALS
35 – Profitability & Financial Ratio Analysis
Page 36 – Balance Sheet Metrics
– Assets and Liabilities indexed to industry revenue at 100
– 16 Current & Non-Current Assets Categories
– 15 Short-term, Long-term Liabilities, & Net Worth
37 – OPEX
– Industry OPEX Analysis
– 2017-2025 Trends, 2026 & 2030 Forecasts
38 – OPEX by Company & Plant
– OPEX per Company & Plant
– 2017-2025 Trends, 2026 & 2030 Forecasts
Page 39 – OPEX Detail
– 6 Employee Expense Categories
– 8 Cost of Material Categories
– 6 Buildings and Equipment Categories
– 8 Other Operating Expense Categories
-Inventory Breakdown: finished goods, work-in-progress, materials and supplies
40 – Production Material Costs & Tariff Analysis
– Top Production Material Costs Breakdown
– Industry & Material Tariff Analysis – % of costs, import %, tariff costs, source countries
41 – Producer Pricing Index
– 2017-2025 Trends, 2026 & 2030 Forecasts
– Monthly PPI Figures for the Past 4 Years
42 – Plant Utilization & Hours
– Plant Utilization Rate
– Plant Operational Hours per Week
– 2022-2025 Historical Figures by Quarter
43 – Reasons for Non-Full Production
– 7 Categories Quarterly Survey Results for Past 2 Years
44 – Productivity & Employment
– Revenue per Employee
– Total Number of Employees
– Employees per Company
– 2017-2025 Trends, 2026 & 2030 Forecasts
45 – Employee Productivity by Segments
46 – Employee Productivity by State
47 –Subsector Sales & Payroll per Employee
48 – Payroll
– Payroll per Employee, Company, & Plant
– 2017-2025 Trends, 2026 & 2030 Forecasts
49 – Payroll per Company by Segments
50 – Payroll per Plant by Segments
51 – Payroll per Employee by Segments
52 – Payroll per Employee by State
53 – Employee Composition
– % of Employees for 27 Job Categories
54 – Job Categorization Pay Ranges
– Pay Bands – Bottom 10% & 25%, Mean, Top 25% & 10%
55 – Top 20 Jobs Breakdown
56 – Top 20 Jobs Pay
– Pay Bands
57 – Employees per Company by Segments
58 – Employees per Plant by Segments
59 – Facilities per Company by Segments
60 – Total Employment by State
61 – Population to Every Employee by State
62 – Employees per Facility by State
63 – Overview of Kentley Insights
Download a Sample Report
Below is a free sample report download. The 2026 Aluminum Casting Operations Market Report has the same layout and data sets as the sample report.
Product Lines, Materials, and Jobs Covered in Report
PRODUCT LINES
Aluminum foundries (except die-casting)
MATERIAL COST CATEGORIES
Materials, ingredients, containers, and supplies, nsk
Aluminum and aluminum-base alloy scrap (excluding home scrap)
Cost of all other materials and components, parts, containers, and supplies consumed
Misc. aluminum-base alloy shapes and forms, including powder
Nonmetallic minerals, including stone, sand, refractory minerals, and chemical materials, excluding fertilizer materials
Misc. fabricated metal products (excluding hardware, containers, screw machine, bearing components, castings, forgings, and wire)
Misc. copper-base alloy shapes and forms (exclud. wire products, ingot, castings, cathodes, anodes, pipe, tube, rods, bar)
All basic organic and inorganic chemicals, excluding petrochemicals
INDUSTRY JOBS ANALYZED
Molders and Molding Machine Setters, Operators, and Tenders, Metal and Plastic
Machine Tool Cutting Setters, Operators, and Tenders, Metal and Plastic
Metal Furnace Operators, Tenders, Pourers, and Casters
Inspectors, Testers, Sorters, Samplers, and Weighers
First-Line Supervisors of Production and Operating Workers
Miscellaneous Production Workers
Industrial Machinery Installation, Repair, and Maintenance Workers
Machinists
Computer Control Programmers and Operators
Maintenance and Repair Workers, General
Industrial Engineers, Including Health and Safety
Laborers and Material Movers, Hand
Tool and Die Makers
Miscellaneous Assemblers and Fabricators
Welding, Soldering, and Brazing Workers
Crushing, Grinding, Polishing, Mixing, and Blending Workers
Miscellaneous Metal Workers and Plastic Workers
Engineering Technicians, Except Drafters
Shipping, Receiving, and Traffic Clerks
General and Operations Managers
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