Metal Casting Market – Global Industry Size, Share, Trends, Opportunity, and Forecast, Segmented By Vehicle Type (Passenger Cars, Light Commercial Vehicles, Heavy Commercial Vehicles), By Electric Vehicle Type (Battery Electric Vehicle, Hybrid Electric Vehicle, Plug-In Hybrid Electric Vehicle), By Material Type (Aluminium Casting, Cast Iron, Magnesium Casting, Zinc Casting, Others), By Application (Body Assemblies, Transmission Parts, Engine Parts), By Region & Competition, 2021-2031F

Forecast Period	2027-2031
Market Size (2025)	USD 172.45 Billion
CAGR (2026-2031)	7.36%
Fastest Growing Segment	Engine Parts
Largest Market	Asia Pacific
Market Size (2031)	USD 264.07 Billion

Market Overview

The Global Metal Casting Market will grow from USD 172.45 Billion in 2025 to USD 264.07 Billion by 2031 at a 7.36% CAGR. Metal casting is a manufacturing process in which molten metal is poured into a mold and allowed to solidify into a specific geometric shape. The global market is primarily driven by the escalating demand for lightweight components in the automotive sector and sustained investments in infrastructure and construction projects. Indicating strong performance in key industrial regions, according to the American Foundry Society, in 2025, casting sales are projected to increase by 4.2 percent to reach 50.1 billion dollars.

Despite this upward trajectory, the industry encounters a significant challenge regarding the volatility of raw material prices and energy costs. These fluctuations create financial instability for manufacturers, complicating long-term planning and squeezing profit margins. Consequently, the unpredictability of input costs serves as a major restraint that could impede broader market expansion and limit capital investment capabilities.

Key Market Drivers

The surging demand for lightweight components in electric and hybrid vehicles constitutes a primary catalyst for the global metal casting market. As automotive manufacturers strive to enhance battery range and fuel efficiency, there is a critical shift towards replacing heavy ferrous parts with high-strength aluminum and magnesium alloys. This transition is further accelerated by the adoption of advanced giga-casting techniques, which allow for the production of massive, single-piece vehicle underbodies, thereby reducing assembly complexity and overall weight. The impact of this automotive transformation is evident in the recent performance of major casting suppliers who are scaling operations to meet these needs. According to Ryobi Limited, November 2025, in the 'Consolidated Financial Results for the Nine Months Ended September 30, 2025', the company reported consolidated net sales of 227.79 billion yen, explicitly attributing financial growth to increased die casting production volumes for the automotive sector.

Simultaneously, the expansion of renewable energy installations, specifically wind turbine components, is generating substantial demand for large-scale metal castings. Modern offshore and onshore wind farms require immense structural parts such as hubs, rotor shafts, and bedplates, which are predominantly manufactured through specialized casting processes. To meet this growing requirement, suppliers are aggressively investing in capacity upgrades. For instance, according to Baettr, December 2025, in a statement regarding its manufacturing expansion in India, the company announced a project to increase its annual casting production capacity from 27,500 tonnes to 95,040 tonnes. Highlighting the broader trajectory of the sector, according to the American Foundry Society, July 2025, in the 'Metalcasting Forecast & Trends' report, the overall market is projected to experience a 1.9 percent increase in casting sales for the year.

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Key Market Challenges

The volatility of raw material prices and energy costs constitutes a formidable barrier to the growth of the global metal casting market by destabilizing the financial foundation of manufacturing operations. Metal casting is inherently energy-intensive, requiring substantial power for melting furnaces, while also depending heavily on scrap metal and virgin alloys whose prices are subject to rapid global market fluctuations. This unpredictability complicates cost estimation and contract negotiations, often forcing manufacturers to absorb sudden cost spikes that severely compress profit margins. Consequently, the inability to forecast expenses accurately deters companies from committing to essential capital expenditures, modernization, or capacity expansion, which are critical for long-term market development.

Highlighting the impact of this uncertain business environment, according to the European Foundry Association, in October 2025, the European Foundry Industry Sentiment Indicator decreased to a level of 94.3 points. This downturn in industry confidence underscores how persistent cost instability hampers strategic decision-making and market optimism. Instead of focusing on growth initiatives, foundries are compelled to conserve resources to weather potential price surges, thereby directly retarding the industry's broader economic potential and limiting its pace of expansion.

Key Market Trends

The Integration of Additive Manufacturing for Complex Mold and Core Production is revolutionizing the sector by eliminating the need for expensive physical patterns and traditional tooling. Foundries are increasingly deploying 3D sand printing binders to accelerate prototyping and manufacture intricate geometries that were previously impossible, significantly compressing lead times for low-volume, high-complexity parts. This technological shift is evidenced by the surging financial performance of key equipment providers. According to Voxeljet AG, April 2024, in the 'Annual Report 2023', the company's systems revenues experienced a notable rise of 37.6 percent to reach 21.8 million euros, directly reflecting the intensifying industrial uptake of high-speed, large-format 3D printers for casting applications.

A distinct Shift to Sustainable Casting Practices and Closed-Loop Recycling is fundamentally reshaping operational priorities as manufacturers strive to meet stringent decarbonization targets and customer mandates. Foundries are actively moving beyond simple compliance, directing substantial capital toward reclamation systems that maximize the reuse of sand and scrap metal to minimize their environmental footprint. Validating this sector-wide commitment to green manufacturing, according to the American Foundry Society, January 2024, in the 'Metalcasters Quarterly Outlook Survey', 26 percent of North American foundries specifically identified environmental controls as a primary area for capital investment in the upcoming year.

Segmental Insights

The Engine Parts segment is emerging as the fastest-growing category within the Global Metal Casting Market, driven by the automotive sector's intense focus on vehicle weight reduction and fuel efficiency. Manufacturers are increasingly utilizing aluminum and magnesium casting techniques to create lighter engine blocks and cylinder heads, effectively replacing heavier traditional materials. This shift is largely a strategic response to strict emission regulations and fuel economy targets enforced by regulatory authorities such as the U.S. Environmental Protection Agency. Consequently, the demand for precision-cast engine components continues to rise to support the production of modern internal combustion and hybrid vehicles.

Regional Insights

Asia Pacific maintains a leading position in the global metal casting market due to substantial manufacturing output in China and India. The region experiences high demand from the automotive and construction sectors, where cast components are essential for vehicle production and infrastructure development. Favorable government policies promoting industrialization, such as initiatives to expand domestic manufacturing capabilities, further strengthen regional market performance. Additionally, the availability of raw materials and established production facilities allows this region to support large-scale supply chains, effectively satisfying the continuous requirement for industrial machinery and heavy equipment.

Recent Developments

• In July 2025, Georg Fischer signed an agreement to divest its automotive casting business to Nemak, a global provider of lightweighting solutions. The transaction, valued at approximately USD 336 million, included nine production sites across the United States, Europe, and China. This strategic move allowed Georg Fischer to focus on its other core divisions while enabling Nemak to expand its portfolio of complex aluminum and magnesium components. The acquisition was intended to bolster Nemak's capabilities in high-pressure die casting and reinforce its presence in the e-mobility and structural chassis sectors.
• In September 2024, Bühler completed the construction of its first megacasting machine, the Carat 610, at its manufacturing facility in Holland, Michigan. This milestone marked the company's first production of such a large-scale die-casting system within North America, featuring a locking force of 61,000 kilonewtons. The machine was built for a specific automotive manufacturer in the region to produce large, complex structural parts like single-piece underbodies. By manufacturing these massive systems locally, the company aimed to reduce logistical costs and carbon emissions associated with transoceanic shipping while enhancing responsiveness to the evolving automotive market.
• In May 2024, Ryobi Die Casting announced a major strategic investment of USD 50 million to expand its manufacturing facility in Irapuato, Mexico. This initiative was designed to increase production capacity in response to growing demand within the electric vehicle market. The expansion plan included the construction of an additional 91,500 square feet of manufacturing space and the installation of five new large high-pressure die cast machines. Company leadership indicated that this development would create over 100 new jobs and strengthen the firm's position as a key supplier of complex aluminum powertrain and structural components in North America.
• In April 2024, Endurance Technologies approved a significant capacity addition for aluminum die casting and machining of automotive components. The company announced plans to install new high-end technology machines primarily for the production of machined clutch and transmission housings for four-wheelers at its existing manufacturing facilities in Chakan, India. This project, requiring an investment of INR 631 million, was initiated to meet demand from a new customer. The capacity expansion was scheduled to be completed in stages, aiming to increase the monthly output by 8,300 casting parts upon full implementation.

Key Market Players

• BONIDE Products LLC
• Corax Bioner Co.
• Certis USA L.L.C.
• Ecoworm Limited
• Kao Corporation
• OHP, Inc.
• PROMISOL S.A.
• SPAA SRL
• Vellsam Materias Bioactivas S.L.
• Victorian Chemical Company Pty Ltd.

By Vehicle Type	By Electric Vehicle Type	By Material Type	By Application	By Region
Passenger Cars Light Commercial Vehicles Heavy Commercial Vehicles	Battery Electric Vehicle Hybrid Electric Vehicle Plug-In Hybrid Electric Vehicle	Aluminium Casting Cast Iron Magnesium Casting Zinc Casting Others	Body Assemblies Transmission Parts Engine Parts	North America Europe Asia Pacific South America Middle East & Africa

Report Scope:

In this report, the Global Metal Casting Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

• Metal Casting Market , By Vehicle Type:

• Passenger Cars
• Light Commercial Vehicles
• Heavy Commercial Vehicles

• Metal Casting Market , By Electric Vehicle Type:

• Battery Electric Vehicle
• Hybrid Electric Vehicle
• Plug-In Hybrid Electric Vehicle

• Metal Casting Market , By Material Type:

• Aluminium Casting
• Cast Iron
• Magnesium Casting
• Zinc Casting
• Others

• Metal Casting Market , By Application:

• Body Assemblies
• Transmission Parts
• Engine Parts

• Metal Casting Market , By Region:

• North America
• United States
• Canada
• Mexico
• Europe
• France
• United Kingdom
• Italy
• Germany
• Spain
• Asia Pacific
• China
• India
• Japan
• Australia
• South Korea
• South America
• Brazil
• Argentina
• Colombia
• Middle East & Africa
• South Africa
• Saudi Arabia
• UAE