United States Automotive Parts Aluminum Die Casting Market Size, Share & Trends Analysis Report By Production Process (Pressure Die Casting, Vacuum Die Casting, Squeeze Die Casting, Gravity Die Casting), By Vehicle Type (Internal Combustion Engine Vehicles (ICEV), Electric Vehicles), By Sales Channel (Original Equipment Manufacturers (OEMs), Aftermarket), By Application (Engine Parts, Transmission Part, Suspension Components, Battery and related components, Others) and Forecasts, 2025-2033

United States Automotive Parts Aluminum Die Casting Market

The United States automotive parts aluminum die casting market size was valued at USD 3.94 billion in 2024 and is estimated to reach from USD 4.21 billion in 2025 to USD 7.24 billion by 2033, growing at a CAGR of 7.0% during the forecast period (2025–2033). This market has experienced robust growth due to increasing demand for lightweight and energy-efficient vehicles. As automakers strive to meet stringent environmental standards, this metal is increasingly being utilized to manufacture automotive parts like engine blocks, transmission housings, and body frames. Furthermore, with major manufacturers such as Ford, Tesla, and General Motors adopting this die casting in their production processes, the U.S. is a key player in this market.

United States Market Growth Factor

High demand for electric vehicles (EVs)

The rising adoption of electric vehicles in the U.S. is a critical driver for the regional market. EVs, which are generally heavier than traditional vehicles due to their batteries, rely on lightweight materials like this metal to offset this weight and enhance battery efficiency.

Tesla's use of massive aluminum die-cast parts, including its single-piece rear underbody for the Model Y, exemplifies how automakers are incorporating this casting to reduce manufacturing costs and improve vehicle performance. Additionally, the Biden administration's goal to have EVs makeup 50% of all new vehicle sales by 2030 will likely fuel further demand for this die casting. Thus, the push for electrification is creating new opportunities for aluminum usage across the automotive sector.

US Market Restraint

Impact of trade policies and tariffs

Trade policies and tariffs have been a significant restraint in the United States. The U.S. has imposed tariffs on aluminum imports from major producing countries like China, resulting in increased raw material costs for domestic manufacturers. The Section 232 tariffs on imported aluminum, for instance, have raised the price of raw materials, leading to higher production costs for U.S. automakers.

The Aluminum Association reports that the tariffs have caused a price increase of up to 25% on aluminum imports, affecting the cost competitiveness of U.S.-made aluminum parts. This volatility in trade policies, coupled with reliance on imported aluminum, presents a challenge for U.S. manufacturers seeking to maintain profitability while navigating an unpredictable trade landscape.

US Market Opportunity

Growth of domestic production

The U.S. is experiencing a resurgence in domestic aluminum production, driven by the automotive industry's increasing demand for this die casting. Recent investments by key producers, such as Alcoa and Novelis, in expanding their production capacity within the U.S. present a significant opportunity for the market. These companies are developing more sustainable production methods, including low-carbon aluminum smelting technologies, to meet the rising demand for eco-friendly materials in the automotive sector.

Additionally, the Infrastructure Investment and Jobs Act, passed in 2021, allocates billions of dollars to modernizing infrastructure, including domestic manufacturing capabilities. This increased focus on boosting local production will help mitigate the impact of tariffs and trade restrictions, creating a more stable supply of aluminum for die casting in the automotive industry.

Regional Insights

The United States holds the largest share of the North American market, driven by its strong automotive manufacturing base, surging adoption of electric vehicles, and commitment to innovation.

• For instance, according to IEA, in the United States, new electric vehicle registrations reached 1.4 million in 2023, reflecting an increase of almost 40% relative to 2022. Michigan, Ohio, and California are among the key regions for die casting production, with several manufacturers and suppliers clustered in these states. The Midwest, in particular, benefits from a well-established supply chain and proximity to major automakers such as Ford, General Motors, and Stellantis. Additionally, the push towards electric vehicles is further concentrated in regions like California, where Tesla and other EV manufacturers are expanding operations.

California's Zero-Emission Vehicle (ZEV) Program, aimed at reducing vehicle emissions, has incentivized the use of lightweight materials like aluminum, boosting market growth. Furthermore, several automakers are investing heavily in die-casting technologies, including Ford's Advanced Manufacturing Center in Michigan, which focuses on lightweight materials for electric vehicles. Thus, the United States automotive parts aluminum die casting market is expected to grow steadily, supported by technological advancements and favorable government policies aimed at promoting sustainable manufacturing practices.

United States Market Segmental Analysis

By Production Process

Pressure Die Casting dominates the production process segment and is estimated to grow at a CAGR of 7.3%. The pressure die casting segment in the United States automotive parts aluminum die casting market is experiencing robust growth due to its ability to produce high-quality, lightweight components with excellent dimensional accuracy. This method is favored by automakers for its efficiency in mass production, cost-effectiveness, and ability to create complex parts with minimal machining. Its increasing use in electric vehicles (EVs) and internal combustion engine (ICE) vehicles further drives demand.

By Vehicle Type

ICE is estimated to own the vehicle type segment and is anticipated to expand at a CAGR of 5.5%. The internal combustion engine (ICE) vehicle type segment remains dominant in the U.S. market despite the rise of electric vehicles. This segment is expanding as automakers continue to incorporate aluminum die-cast parts into engines and transmissions to reduce vehicle weight and improve fuel economy. The need to meet federal fuel efficiency standards, alongside sustained consumer demand for gasoline-powered vehicles, drives the growth of this die casting in ICE vehicles.

By Sales Channel

Original Equipment Manufacturers (OEMs) dominate the sales channel segment and are expected to augment at a CAGR of 7.4%. The OEM segment is growing in the United States automotive parts aluminum die casting market due to the rising demand for lightweight materials that enhance vehicle performance and meet stringent fuel efficiency standards. OEMs are increasingly adopting this die-cast components to produce engines, transmissions, and structural parts. The push for electrification and the need to reduce carbon emissions also drive OEMs to integrate aluminum parts to enhance battery efficiency and vehicle range.

By Application

Engine Parts dominates the application segment and is estimated to grow at a CAGR of 6.4%. The engine parts application segment is expanding due to the increasing use of this casting for producing lightweight, durable engine components. Automakers prioritize this metal for parts like engine blocks, cylinder heads, and pistons to reduce overall vehicle weight and improve fuel efficiency. Additionally, the material's high thermal conductivity enhances engine performance. The ongoing demand for both ICE and hybrid vehicles further accelerates the growth of this segment.

Analyst's Perspective

As per our research analysts, the United States automotive parts aluminum die casting market is poised for long-term growth, driven by environmental regulations, electrification, and advancements in die casting technologies. While trade policies and tariffs present challenges, the increasing focus on domestic aluminum production offers a viable solution to offset these issues. With a growing emphasis on lightweight materials to improve vehicle efficiency and performance, aluminum die casting will continue to play a critical role in the U.S. automotive sector. Additionally, automakers that invest in advanced manufacturing processes and sustainable materials will be well-positioned to capitalize on the evolving market dynamics.