High integrity aluminum castings engineered for tomorrow, built by a proprietary electromagnetic metal delivery system, not gravity.
50+
Years casting aluminum
ISO 9001:2015
Certified quality system
PED 2014
Pressure equipment certified
TÜV
Rheinland certified
USA
Made in Peoria, Illinois
Mitchener Molding Machines are designed, built, and maintained in-house in Peoria.
Alcast combines proprietary electromagnetic bottom filling, triple-filtered aluminum, and controlled solidification to produce complex-cored, pressure-tight, cosmetic, and large structural castings with exceptional consistency.
01
Integrity begins before the mold fills: electric melting, controlled alloy chemistry and triple filtration keep oxides and inclusions from becoming casting defects.
02
The electromagnetic metal delivery system moves aluminum from furnace to mold without ladling or free fall.
03
Metal should enter the mold, not fall into it. Filling from below reduces the folding, splashing and air entrainment of gravity pouring.
04
PLC-controlled fill rate and pressure, with mold cooling, in permanent and semi-permanent tooling for sound, repeatable parts.
Conventional Casting
Same Part. Different Result.
If a part is fighting porosity, leaks or scrap in a conventional pour, send it to us and see what controlled metal does for it.
Why Alcast
From precision production components to castings approaching 1,000 pounds, we solve the applications that push conventional gravity and low-pressure processes beyond their limits.
The Mitchener Process
Our proprietary Mitchener process doesn't pour metal, it delivers it: an electromagnetic system fills every mold from the bottom up with triple-filtered aluminum.
From heavy equipment to marine and aerospace, our castings run inside the machines that can't afford to fail.
Complex geometry should not require compromised integrity. Intricate shapes, ribs and bores, cast for repeatable production.
Steel cores, shell cores and complex core assemblies let us consolidate components and cast difficult internal passages.
Castings designed for applications where internal integrity and leak resistance are critical.
Consistent surfaces for components where appearance, coating, and final finish matter.
High integrity is no longer limited to small castings. We cast beyond the size range most permanent mold systems are built to handle.
We design, build, and maintain our own casting machines: less downtime, lower cost, full control.
From a 5-piece prototype run to 500,000+ pieces a year, on the same proprietary platform.
Our tooling and quality engineers work with you from the first sample castings through approval, so new parts get into production sooner.
Quality is measured after it is engineered. Pressure testing, X-ray NDT, dimensional validation and process control verify every part.
From complex geometry to pressure-tight components, Alcast helps move challenging parts into reliable production.
Vertically Integrated
From molten metal to a finished, machined part, Alcast keeps every stage under one roof: one team, one point of accountability.
Electromagnetic bottom-fill casting
Sand cores for complex internal geometry
Gentle, low-turbulence fill for select parts
Via ACC: complex shapes, low-volume runs
Precision finishing to exact print
Controlled cycles for strength & consistency
Verifying internal integrity, part by part
Finishing, powder coat, plating & more
Send us the print. An Alcast engineer will map it to the right casting method and every step after it, from first pour to finished part.
How It Works
Five simple steps, one team the whole way.
Step 1
Fill out a quick RFQ form or call us. We can quote from electronic files or blueprints.
Step 2
Our engineers check your design for castability, recommend the right process and send your quote.
Step 3
We cast sample parts, then prove production tooling with full-dimensional inspection before launch.
Step 4
Your parts are cast, heat treated, machined and finished in-house, then shipped ready to install.
Step 5
On-time shipping and ongoing quality support long after launch, backed by a commitment to zero defects.
Already have tooling? We'll transfer it →
Industries We Serve
From torque converters to marine housings, Alcast castings run inside the machines that can't afford to fail.
In the Field
Hydraulic valve bodies and hydrostatic transmission housings for the machines that can't go down.
Powertrain
Ventilation & Compressor
Racing & Automotive
Industrial Equipment
Marine
Power Generation
In the Field
Pressure-containing housings and large structural castings built for salt, vibration and years at sea.
Our History
1970
Founded in Peoria, IL
Alcast has been engineering high-integrity aluminum castings from Peoria, Illinois since 1970, one of a select group of American foundries built around proprietary electromagnetic metal delivery. We design, build, and maintain our own casting and core machines in-house, keeping downtime low and our cost structure lean enough to quote competitively without compromising precision.
Advanced quality planning, tight process control, and on-time shipping make us less of a supplier and more of a partner invested in your business. As part of the Ligon Permanent Mold Group, a family of vertically-integrated aluminum casting foundries, we pair that independence with the resources of a larger group of North American foundries.
About Alcast →
Today
Foundry floor, Peoria, IL
What You Can Count On
Proprietary electromagnetic Mitchener machines
Advanced quality planning & tight process control
On-time shipping, every time
Cored, heat treated, machined & powder coated
A partner invested in your business, not just a supplier
From early design through production, Alcast works with manufacturers to turn demanding aluminum components into reliable castings.