Metal Casting Market

Market Overview

The global metal casting market size was valued at USD 26.43 billion in 2022. It is projected to reach USD 55.53 billion by 2031, growing with a CAGR of 8.6% during the forecast period (2023–2031).

In metal casting, metal shapes are created by pouring molten metal into a mold cavity, where it is allowed to cool and is then extracted. It facilitates the production of complex, large-scale components for numerous industrial applications. Metal castings are used in a wide array of industries such as transport, heavy equipment, machine tools, plant machinery, defense, electrical equipment machines, hardware, household, art objects, and others. The metal casting market is growing at a tremendous rate as there is imminent demand from emerging sectors. Transport and heavy equipment are the predominant consumers in the metal casting market, producing 50% of the casting. Moreover, a body assembly component in vehicle manufacturing is the key growth factor for the metal casting market. With the increasing adoption of X-ray casting defect recognition systems, the global metal casting market is expected to witness significant growth during the forecast period. Furthermore, technology such as digital imaging and digital radiography allows process inspectors to detect any casting error, which will likely push the metal casting market growth. 

Market Dynamics

What are the factors driving the market growth?

Emission and Fuel Efficiency Guidelines

Increasing vehicle production, rising demand for lightweight vehicles, and growing stringency in emission & fuel efficiency guidelines are projected to drive the metal casting market growth during the forecast period. According to the International Organization of Motor Vehicle Manufacturers, over 79 million vehicles were produced in 2021, which is expected to increase in the near future. As per the U.S. Department of Energy, using lightweight casting materials, namely magnesium and aluminum alloy, can reduce the weight of the body & frame by up to 50%. This is further helping the manufacturers to meet the stringent emission and fuel efficiency targets set by the European Union (EU) and the U.S. Environmental Protection Agency (EPA).

What are the factors restraining the market growth?

3D Printing

Increasing 3D printing will supplant traditional die metal casting techniques. The results of 3D printing are more realistic and robust than those of die metal casting. The adoption of technologies quickens the printing of any form of silicone, composite material, metal, plastic, or sand in energy-based additive manufacturing. It provides producers with the capacity for flexible designing, rapid prototyping, waste minimization, lightweight and sturdy components, easy access, and cost-effectiveness while decreasing the demand for metal casting.

Segmental Analysis

The global metal casting market is segmented by process, application, material type, components, and end-user.

On the basis of the process, the market is segmented into gravity, high-pressure die casting, low-pressure die casting, and sand casting.

The High-pressure die casting (HPDC) segment is likely to be the fastest-growing segment in the market. This is attributed to process advantages such as shorter cycle time, excellent finished products, higher dimensional accuracy for larger and more complex parts, and the best fit for mass production.

On the basis of application, the market is segmented into body assembly, engine parts, transmission parts, medical devices, and others.

The huge contribution of body assembly to overall vehicle weight and increased use of lightweight resources in body assembly components are the major factors that may raise the demand for the product.

On the basis of material type, the market is segmented into aluminum, cast iron, magnesium, zinc, and others.

Aluminum is expected to hold the largest share of the market owing to its durability and providing greater fuel efficiency, better handling, acceleration, and braking. According to European Aluminium Association, the standard aluminum content in a passenger car was approximately 150 kg in 2015. Moreover, the engine and transmission parts together contribute to 36%, while wheels own 20%. Furthermore, an increase in demand for aluminum cast components for power trains and body assemblies are thus projected to rise in the forecast period, which is expected to drive the market.

On the basis of components, the market is segmented into alloy wheels, battery housing, cross-car beam, clutch casing, crankcases, cylinder heads, engine block, differential cover housing, engine mount, flywheel housing, front door and rear door frame, exhaust & intake manifold, gearbox housing, ignition & lock housing, transmission housing & turbocharger housing, and others.

The engine block segment is likely to hold the major share in the market due to its lightweight property.

On the basis of end-user, the market is segmented into automotive, medical devices manufacturer, chemical, and others.

The automotive segment is expected to hold the major share in the market owing to growing vehicle production, increasing trend for lightweight vehicles, and growing stringency in emission & fuel efficiency regulations.

Regional Analysis

Geographically, the global metal casting market is segmented into North America, Europe, Asia Pacific, Latin America, and Middle East & Africa.

The Asia Pacific is expected to lead the global metal casting market owing to the increasing production of passenger cars and electric vehicles. China is likely to hold the leading automobile market in vehicle production as well as sales. According to the International Organization of Motor Vehicle Manufacturers (OICA), China, along with Japan and India, accounted for approximately 44% of global vehicle production in 2016. Furthermore, as per the World Bank statistics, the per capita income in China and India increased by almost 68% and 14%, respectively, from 2010 to 2015. The rise in income is expected to raise the sales of medium and premium-end vehicles, which would boost the demand for aluminum and magnesium-cast components in the region. In addition, metal casting manufacturers in the region have implemented simulation-based castings to generate flawless, defect-free products, minimizing operational waste and expenses.

Europe is expected to witness significant growth in the metal casting market owing to the new technology implementations in the automotive sector. Moreover, automotive sector developments in Europe are mainly in Germany, which includes lightweight components, cast substitutions, and advanced development of composite structural parts. As metal casting contributes to the enhancement of energy efficiency, the reduction of manufacturing costs, the improvement of environmental quality, and the creation of inventive new cast products, its demand is increasing across numerous industries. In addition, governments in a number of nations are setting tough regulations on the carbon emissions of vehicles, which is driving up demand for lightweight metal casting products in the region. In addition, technological advances, such as computer-based visualization for die casters, are projected to have a beneficial effect on market expansion in the next years.

North America is likely to be the developing region for the metal casting market. The major trend witnessed in the metal casting machinery market in North America is the casting process which incorporates simulation technology. This simulation technology helps in producing reliable, high-precision, and cost-effective components through the casting method, which increases the market in North America. In North America, both the demand and manufacturing of automobiles are on the rise. This is increasing the demand for iron castings, widely employed in the production of engine components. A vast array of iron-cast parts and components are used in the assembly and production of lightweight trucks and passenger cars. The United States maintains the highest proportion of the North American metal casting market due to the country's high concentration of manufacturers and end-users. Large-scale automobile plants, machinery & tool makers, a growing demand for pipes & fittings due to the expansion of the petrochemical industry, and improvements in infrastructure are driving the demand for this commodity in the country.

The Middle East & Africa is expected to hold the least share of the metal casting market. There is growth in the automotive industry in Africa which leads to the rise in metal casting. Future market development of the metal casting market can be expected as there is a low cost for raw materials and labor. Latin America is likely to display sluggish growth in the market, as only three countries have an established foundry industry, as there is a lack of electric power, raw materials, and well-trained manpower.

Recent Developments

• March 2022- Linamar Corporation announced an agreement with GF Casting Solutions to buy GF Casting Solutions' 50% stake in their North Carolina-based joint venture, GF Linamar LLC.
• March 2021- Ermak Foundry and Machining of Minnesota has acquired Patriot Foundry & Castings, a maker of nonferrous sand castings, and RDS Dock Gear, a manufacturer of aluminum docks, decks, and bridge hardware.

Metal Casting Market Segmentation

By Process

• Gravity
• High-pressure die casting (HPDC)
• Low-pressure die casting (LPDC)
• Sand casting

By Application

• Body assembly
• Engine parts
• Transmission parts
• Medical Devices
• Other

By Material Type

• Aluminum
• Cast iron
• Magnesium
• Zinc
• Others

By Components

• Alloy wheels
• Battery housing
• Cross-car beam
• Clutch casing
• Crankcases
• Cylinder heads
• Engine block
• Differential cover housing
• Engine mount
• Flywheel housing
• Front door and rear door frame
• Exhaust & intake manifold
• Gearbox housing
• Ignition & lock housing
• Transmission housing & turbocharger housing
• Others

By End User

• Automotive
• Medical Devises Manufacturer
• Chemical
• Other

By Region

• North America
• Europe
• Asia Pacific
• LAMEA