From welded part to casting

Welded sheet-metal assemblies consist of many individual parts. Every weld seam introduces heat and causes distortion, rework is the rule – and production can hardly be scaled.

We turn such assemblies into a one-piece aluminium casting. As a sand-cast prototype it can be tested quickly and later forms the basis for series production by die casting. In our experience, the cost saving is around 25 % even at the sand-cast prototype stage.

When is it worth it?

Many parts and seams: many individual parts become one component cast in one piece.
Distortion and rework: a casting has no welding distortion; we straighten directly after solution annealing.
Weight: aluminium instead of steel makes moving assemblies lighter – for higher acceleration and more agile drives.
Integrate functions: ribs, cooling fins for passive cooling, mounting points and housing shapes can be cast in directly.
Growing quantities: if the prototype turns into a series, the casting is the basis for die casting.

How it works

Your 3D files: the welded assembly as STEP or IGES, plus the functional and mounting faces.
Designing the casting: we derive a castable part – with draft angles, sensible ribbing and wall thicknesses as uniform as possible – and check it by casting simulation.
Casting the prototype: cast a first part, assess it and use it to set up machining; heat treatment in-house.
Machining and inspection: wherever possible as 5-sided machining in a single clamping, inspection e.g. by X-ray and measuring arm.
Test and series: changes are incorporated after testing; the casting serves as the basis for later series production by die casting.

What does it cost?

In our experience, even the sand-cast prototype is around 25 % cheaper than the welded construction. Rough, non-binding guide values (net, as of 10/2026):

Pattern equipment (one-off): medium-sized parts approx. 400–8,500 €, large parts up to approx. 20,000 €
Unit price including machining: usually approx. 150–700 €
Repeat orders: usually only set-up costs of approx. 15–200 €

All guide values: guide prices for aluminium sand casting

Frequently asked questions: from welded part to casting

Often yes – especially with many individual parts and seams, with distortion and rework, when weight is to be saved or when quantities grow. In our experience, even the sand-cast prototype is around 25 % cheaper than the welded construction.

Yes. From the 3D files of your welded assembly and the functional faces, we derive a castable part and check it by casting simulation.

Typically 2.5 to 4.5 weeks. For express orders, it takes approx. 2 calendar weeks to the cast part; express orders cost more.

Aluminium is lighter but less stiff than steel. We compensate for this in the design, for example with ribs and adapted wall thicknesses. We clarify the required properties with you.

Yes. The sand-cast prototype forms the basis for later series production by die casting. We produce prototypes, pre-series and small series; high-volume die casting is taken over by a series supplier.

3D files of the welded assembly as STEP or IGES and the functional and mounting faces. For a preliminary estimate, files of a similar part are enough.

How to reach your goal

Contact us via our contact page with the subject “Price estimate” and include the STEP or IGES files of your welded assembly, quantity, deadline and requirements.

More: Aluminium sand casting · Test your die-cast part · Guide prices and enquiries

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