End-to-end aluminum casting for high-performance thermal components, using controlled pressure casting and gravity-permanent-mold methods optimized for low porosity, repeatability, and precise thermal-mechanical properties. CAS pairs process simulation and controlled solidification to deliver leak-tight, high-yield castings suited to semiconductor, aerospace, and fluid-heating applications.

Metal Casting encompasses all processes where molten or semi-solid metal is poured or injected into a mould and solidified to form billets, slabs, or near-net-shape components. Methods range from continuous billet casting for primary metal production to specialised routes such as sand casting, high-pressure die casting, and semi-solid thixocasting.

Metal Casting

High-pressure or vacuum die casting forces molten aluminum, magnesium or zinc alloys into hardened H-13 steel dies at 5,000–20,000 psi. Fast solidification (milliseconds) yields near-net-shape parts with wall sections as thin as 0.040 in, ±0.002 in / in dimensional accuracy and as-cast surface finish around 200 µin Ra, minimizing secondary machining.

Die Casting

Permanent-mold casting pours molten metal by gravity into reusable iron or steel molds, delivering better mechanical properties and surface finish than sand casting without external pressure.

Permanent-Mold (Gravity) Casting

Finite-element/CFD modelling of metal flow, temperature gradients and solidification kinetics to optimise gating, risering and cooling of aluminum sand or permanent-mold castings before tooling release.

Casting Solidification & Flow Simulation

End-to-end R&D service that engineers proprietary aluminum casting routes—sand, permanent-mold, or die—together with custom alloy chemistries and heat-treatment tempers to meet target mechanical, thermal, and leak-tightness requirements. Deliverables include alloy melt recipes, gating & riser geometry, process parameter windows, and validated test coupons with full metallurgical reports.

Casting Process & Alloy Development

Aluminum Casting & Alloy Development

Comprehensive inspection, metrology and NDT services supporting incoming, in-process and final verification. CAS leverages CMMs, digital X‑ray, ultrasonic testing, profilometry, helium leak and pressure tests to deliver traceable data packages and regulatory-first-article documentation for critical thermal and fluid systems.

Inspection & Quality Control (IQC) comprises the metrology, verification, and documentation activities that ensure parts conform to drawing/CAD requirements, customer specifications, and regulatory standards. IQC spans incoming, in-process, and final inspection and leverages coordinate metrology (CMMs and portable arms), laser/structured-light scanning, optical comparators and vision systems, surface-form metrology (profilometers, roundness/contour testers), nondestructive testing (NDT), and statistical process control (SPC). Results are captured in traceable reports (e.g., AS9102 FAIR, PPAP) tied to calibrated gauges and controlled environmental conditions.

Inspection & Quality Control

Helium mass-spectrometer and differential-pressure decay testing of cast or machined housings, ensuring leak rates as low as 1×10⁻⁶ mbar·L/s for aerospace and fluid-power applications.

Vacuum & Pressure Leak Testing

Uses helium mass-spectrometer methods to confirm hermetic or pressure-tight assemblies meet specified leak-rate limits.

Helium Leak Testing

Ultrasonic Wall-Thickness Testing (UT-WT) uses pulse-echo ultrasonic transducers to measure the remaining wall of tubes, pipes, and structural components without cutting them open. The digital A-scan display and automatic velocity compensation allow rapid detection of thinning, corrosion, or eccentricity while the part remains in service or during incoming inspection.

Ultrasonic Wall-Thickness Testing

Inspection & Quality Assurance

High-precision CNC machining (multi-axis milling and mill-turn) to finish castings and produce functional features to tight tolerances. Scalable from prototype runs to production volumes with in-process probing, pallet automation, and closed-loop SPC to ensure dimensional conformity for thermal and fluid-handling assemblies.

CNC Machining is subtractive manufacturing performed on computer-numerically controlled machine tools. Toolpaths generated from CAM drive multi-axis milling, turning, and mill-turn equipment to remove material accurately and repeatably. The approach enables tight tolerances, stable process capability, and scalable automation for prototypes through production across metals and engineering plastics.

CNC Machining

CNC Milling removes material with rotating cutters under precise multi-axis computer control, producing complex prismatic or sculpted parts with positional accuracy to ±0.005 mm and surface finishes ≤ Ra 0.4 µm. Machines span 3-axis vertical mills, 4-axis horizontals with pallet changers, and full 5-axis trunnion or gantry platforms, supporting everything from rapid prototypes to lights-out production in metals, plastics, and composites.

CNC Milling

CNC Mill-Turn Machining combines multi-axis turning and milling in a single setup. Workpieces are clamped once and processed on opposed spindles with live tooling, Y-axis milling, and simultaneous interpolation up to 9 axes. This eliminates part re-clamping, improves concentricity between turned and milled features, and compresses overall cycle time for complex prismatic-plus-cylindrical components used in aerospace, medical, and high-mix/low-volume production.

CNC Mill-Turn Machining

Performs 3-axis milling with programmable 4th-axis indexer for multi-face machining in one setup (non-simultaneous).

4-Axis CNC Milling (Indexing)

Precision CNC Machining & Finishing

Integrated product development and engineering services: thermal/mechanical FEA, 3-D CAD, DFM/DFT reviews, prototype builds and lab-based thermal performance testing. The New Product Development team bridges design, tooling and production to shorten cycles and produce validated, production-ready thermal components.

Provides end-to-end mechanical design of components and assemblies with integrated finite-element analysis. Engineers create parametric 3-D models, run linear/non-linear static, thermal, vibration, and fatigue simulations, and iterate designs for manufacturability, cost, and compliance. Deliverables include native CAD, detailed drawings, and FEA summary reports.

Mechanical Engineering Design & FEA

Rapid, multidisciplinary build of functional prototypes that bridge industrial design and engineering validation. Combines additive manufacturing, CNC machining, soft tooling, electronics integration, and functional testing in tight sprint cycles to prove form-fit-function and gather user feedback before production tooling.

Prototype Development (Concept-to-Function)

Design-for-manufacturability and design-for-assembly consulting evaluates product designs for optimal manufacturability, assembly cost reduction and quality control. Experts deliver actionable reports on feature simplification, material selection, draft angles and assembly gauge strategies to reduce cycle times and scrap rates.

DFM / DFA Consulting

Engineering, Prototyping & NPD

Value-added finishing and assembly services including anodizing, plating, custom coatings, deburr/edge conditioning, and ISO-class cleanroom assembly & packaging. These secondary operations deliver customer-ready, serializable products (including ESD-safe, sterile or particle-controlled packaging) for semiconductor, medical and aerospace applications.

Surface treatment & finishing encompasses chemical, mechanical and thermal operations—tumbling, vibratory deburr, abrasive blasting, electropolishing, anodizing, chromate conversion, hard-chrome or nickel plating, powder coating, wet painting and ceramic or PVD/CVD overlays—that modify a part’s surface for appearance, corrosion resistance, wear protection or adhesion. Processes routinely achieve ≤ 8 µin Ra finishes, controlled coating thickness from 0.0001 in to 0.010 in and salt-spray performance exceeding 1 000 h to ASTM B117.

Surface Treatment & Finishing

Anodizing is an electrochemical process that enhances the natural oxide layer on metal parts, primarily aluminum. It improves corrosion resistance, wear resistance, and surface hardness, and can also be used for color finishing. Anodizing is essential in industries like aerospace, automotive, and consumer electronics. The process includes Type II for decorative finishes and Type III for hard anodizing, providing a thicker, wear-resistant layer.

Anodizing

This process combines hard anodizing with PTFE impregnation to create a wear-resistant, low-friction surface on aluminum parts. It's ideal in automotive and aerospace where both hardness and lubricity are needed.

PTFE Impregnated Hard Anodize

ISO Class 7–5 clean-room production integrates laminar-flow benches, ESD flooring, HEPA filtration (≥ 99.97 % @ 0.3 µm) and micro-particle monitoring to assemble, package and inspect medical, semiconductor and opto-electronic products. Processes comply with ISO 13485, IPC-A-610G Class 3 and EU GMP Annex 1 for bioburden and particulate control.

Clean-Room Manufacturing & Assembly

Final cleaning, lint-free packaging, vacuum-pouch sealing, and ESD/humidity control for micro-spring lots, executed in ISO 7–8 environments with device-history record (DHR) capture.

Clean-Room Micro-Part Packaging & Handling

Secondary Operations & Value-Added Services

A global standard for quality management systems focusing on continuous improvement and customer satisfaction.

ISO 9001:2015

Involves the fabrication and assembly of electronic components, semiconductor devices, printed circuit boards, and advanced microelectronics, as well as the manufacture of supporting mechanical components such as casings, enclosures, and structural parts. Cleanroom processes, ESD controls, precision machining, and adherence to industry standards (e.g., IPC, JEDEC) are critical for achieving high-density, high-performance products in mass-market, specialized, and ancillary applications.

Electronics & Semiconductors

Cast Aluminum Solutions, LLC manufactures precision-engineered thermal components and cast-in wafer pedestal heaters with integrated heating/cooling and vacuum-compatible features for semiconductor wafer processing equipment used in deposition, etch, and thermal processing chambers.

The development, manufacturing, and supply of precision-engineered medical systems, devices, and critical components, including diagnostic equipment, surgical instruments, implantable devices, laboratory systems, and precision medical components. Emphasizes adherence to ISO 13485 and FDA QSR standards, traceability requirements, sterile processing, rigorous validation, and use of biocompatible materials such as titanium, stainless steel, and medical-grade polymers to ensure patient safety and clinical effectiveness across global healthcare settings.

Medical Devices & Healthcare Equipment

Cast Aluminum Solutions, LLC produces medical-grade precision castings, machined heater assemblies, and cleanroom-assembled components used in medical device manufacturing, diagnostic instruments, and laboratory test fixtures where thermal control and cleanliness are critical.

The design, manufacturing, and integration of high‐precision components, systems, and subsystems for commercial aircraft and military platforms, with emphasis on meeting stringent certifications such as AS9100, ITAR, and MIL‐STD. Priorities include advanced materials, rigorous quality assurance, and robust engineering to ensure reliability in mission‐critical applications.

Aerospace & Defense

Cast Aluminum Solutions, LLC supplies aerospace and defense customers with lightweight cast aluminum motor and pump enclosures, fuel and propellant inline heaters, and heated probes used for engine test stands, fuel line purge systems, and spacecraft thermal interfaces.

Machinery, filling, and packaging solutions for meat, dairy, beverage, and ingredient lines. USDA / FDA sanitary design, corrosion-resistant materials, and high-throughput automation preserve product quality and safety in regulated processing environments.

Food & Beverage Processing

Cast Aluminum Solutions, LLC designs and fabricates cast-in and circulation heater modules, griddles, and steam-generating reservoirs for commercial foodservice equipment OEMs, applied in griddles, bun toasters, beverage heaters, and pasteurization lines.

Upstream exploration and drilling, midstream transport, refining, and integrated petrochemical processing. Designs must withstand high pressure, corrosive media, and hazardous environments while meeting API/ASME and IECEx/ATEX safety standards across global operations.

Oil, Gas & Petrochemical

Cast Aluminum Solutions, LLC provides robust heated flow-tube assemblies, inline circulation heaters, and vaporization solutions for industrial fluid, petroleum, and natural gas applications, including fuel pre-heaters for compressors, generators, and high-pressure fluid handling.

Rigid, flexible, and specialty packaging; high-speed printing and labeling technologies. Efficiency, sustainability, and regulatory compliance drive solutions that protect products and communicate brand value across FMCG, pharma, and industrial supply chains.

Packaging, Printing & Labeling

Cast Aluminum Solutions, LLC engineers heated components and platen solutions for packaging, converting, and printing equipment—custom castings and machined heater assemblies used to control substrate temperature during printing, laminating, and web-processing operations.

Cast Aluminum Solutions, LLC designs and manufactures precision-engineered thermal components and aluminum castings for aerospace, microelectronics/semiconductor, medical device, foodservice and industrial gas & fluid markets. Services include thermal and structural modeling, mold creation, casting (pressure, tilt-pour), multi-axis CNC machining, assembly (including in-house cleanroom), surface finishing, and inspection (CMM, X-ray, ultrasonic). CAS is ISO 9001:2015 certified and offers Rapid Fab programs delivering prototypes and low-volume runs with short lead-times.

Headquarters and primary manufacturing site for precision-engineered thermal components and cast aluminum products. The facility includes full-scale casting and machining operations with dozens of programmable multi-axis CNC machines, multiple CMMs, in-house cleanroom assembly, various plating/coating and joining techniques, and integrated ERP order-tracking. Its Batavia location provides regional supply-chain advantages for the U.S. Midwest via proximity to major highways and distribution networks.

Cast Aluminum Solutions Headquarters

Manufacturer of precision thermal aluminum components and heaters for aerospace, semiconductor, medical, and industrial markets.

Cast Aluminum Solutions

Precision Thermal Aluminum Components

Aluminum Casting & Alloy Development

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