Shaping America's Future
Importance of Die Casting
America’s most fundamental industry, metal casting, continues to play a critical role in the success of U.S. manufacturing through the production of high quality castings and support of key industry sectors. In fact, castings are used in 90% of all finished manufactured products.
As an important segment of the larger metal casting industry, the die casting industry produces over one-third of all metal castings. Today, there are over 300 die casting companies in the U.S. comprising over 375 individual die casting plants, which manufacture thousands and thousands of non-ferrous castings: from automobile engine and transmission parts to intricate components for computers and medical devices.
In the United States, die casters contribute over $8 billion to the nation’s economy annually and provide over 50,000 jobs directly and indirectly.
The die casting industry is a microcosm of American business with over 55% of the companies having fewer than 100 employees, while our larger firms are world leaders.
In the medical field, die casting applications include portable medical monitors, dental X-ray units, electronically operated hospital beds, EKG machines, ultrasound equipment, and other hand-held medical devices.
Medical-Surgical Hospital Bed
Michigan-based Cascade Die Casting Group provides upper and lower transmission housing, side rail carriers and support plates.
Steering the Auto Industry
Today's auto is a complex, integrated product with more than 3,000 parts. Aluminum, magnesium and zinc die castings are helping automakers design and manufacture cleaner, safer, better performing cars that use less fuel and produce fewer emissions. In fact, the metalcasting industry supplies at least 100 castings in every light weight vehicle produced in the U.S. die casters can produce parts for hybrid vehicles, plug-in electric and hydrogen vehicles, as well as vehicles using alternative fuels such as ethanol flexible-fuel and natural gas vehicles.
Motorcycle Tail Section - This single die cast magnesium tail section replaced a four pound aluminum weldment consisting of over twenty five parts. It is made by Twin City Castings of Minnesota.
Key Industries Served
Die casters provide valuable products to all major market sectors including:
- Consumer Products
- Lawn & Garden
- Power Tools
- Sports & Recreation
Casting for a Sustainable Future
NADCA and its member companies embrace continuous innovation and improvement. We apply sustainability principles in the manufacturing and distribution of die castings.
The die casting industry has long been built on recycling. The metal alloys used by die casters are produced from recycled raw materials, created with far less energy than is required for virgin alloys.
Production from Recycled Raw Materials
- Over 95% of the aluminum die castings produced in North America are made of post-consumer recycled aluminum, helping to keep the aluminum content of municipal solid waste to less than 1%.
Energy Savings Equipment
– Increases in energy costs have prompted interest in what can be done to minimize energy usage in die casting plants. Empire Die Casting, an Ohio-based aluminum and zinc die caster, and other plants have installed advanced electric aluminum melting, distribution and holding systems that will cut the amount of energy needed to melt aluminum by 80%. Many die casters have replaced the lighting in their facilities - benefits include lower energy use, better lighting and less heat generated by the lights.
Closed Loop System
– Die casters have successfully implemented a closed loop system to recycle and reuse as much material as possible within their processes. They recycle everything from office paper to hydraulic fluid to machining chips. This results in very little waste being transported to the landfill.
ISO Environmental Certification
– Many die casters have earned their ISO 14001 environmental management system certification. This achievement emphasizes current and future commitment to reducing their environmental impact, through the reduction of waste water, energy and solid waste.
Helmet Mount for Night Vision Goggles - Kinetic Die Casting – California.
Premier Die Casting of New Jersey produces the castings for the docking and pay stations for several US-based bike sharing systems.
Growth in Renewable Energy Castings
Castings also play an integral part of the global energy-production chain. In addition to traditional uses for castings in oil and gas production, they are essential to the growth of renewable-energy sources and in the production of more energy efficient vehicles.
Bio power utilizes several cast components, including industrial fans, pumping equipment, piping and turbines while propellers, pumps and pumping castings are vital to the production of geothermal power.
According to the U.S. Department of Energy (DOE), the areas of most promise for alternative energy resources include biomass, geothermal heat, pumps, hydropower, solar photovoltaic, wind, and energy efficiency. Metal castings will play a key role in the expansion of all renewable energy sources.
“The automation of equipment, new processes, and stringent requirements for casting to perform even more difficult tasks pose great opportunities and challenges to the die casting industry for the future.”
North American Die Casting Association (NADCA)
is the sole trade and technical association of the die casting industry. NADCA membership consists of both corporate and individual members from over 300 companies located in every geographic region of the U.S.
North American Die Casting Association
3250 Arlington Heights Rd - Ste 101
Arlington Heights, IL 60004
Website address: www.diecasting.org