Custom Metal Casting Services
At TFG USA, we provide custom metal casting services for the medical, industrial, and agriculture industries. Founded in 1980, our US-based team delivers aluminum die casting, investment casting, sand casting, and other cast components. We specialize in medium to high-volume production programs backed by decades of global manufacturing expertise and supply chain management.
Request a QuoteWhy Choose The Federal Group for Metal Casting
We help engineers, buyers, and purchasing teams produce reliable custom metal cast components through responsive project management and proven metalworking expertise.
Engineering Expertise
Our engineering team helps optimize custom metal cast components for manufacturability, performance, and long-term reliability.
Quality-Driven Processes
Our in-house quality engineers oversee ISO compliance, manufacturing audits, and strict inspection processes to ensure every casting meets built-to-print specifications.
Supply Chain Support
We coordinate global sourcing, production scheduling, inventory management, packaging, and international logistics to help keep custom metal casting programs on time.
Secondary Operations
We provide complete secondary operations like CNC machining and custom finishing to reduce the need for multiple vendors.
Industries We Serve
Our custom metal casting services provide reliable and high-strength components to some of the most demanding industrial sectors.
Medical Industry
We manufacture custom metal cast components for the medical industry including surgical instrument handles, orthopedic implant components, imaging equipment housings, dental device parts, and medical pump housings requiring tight dimensional control and high-quality surface finishes.
Construction Industry
We produce durable cast metal components for the construction industry including heavy equipment housings, mounting brackets, hydraulic system components, structural supports, and pump bodies engineered for demanding operating environments.
Energy Industry
We manufacture heat and corrosion-resistant cast metal components for the energy industry including valve bodies, turbine housings, pump casings, manifolds, impellers, and structural support components designed for high-performance applications.
Processes and Technologies We Support
Selecting the right metal casting process depends on your part geometry, material requirements, tolerances, and production goals. We support a wide range of casting technologies to manufacture custom metal components across multiple industries.
Die Casting
- Cold Chamber Die Casting: Uses high-pressure injection for aluminum alloys and other higher melting point metals, making it ideal for scalable production.
- Hot Chamber Die Casting: A highly automated process designed for rapid cycle times and lower melting point alloys.
- Multi-Slide Die Casting: Produces complex near-net-shape components that help reduce secondary machining operations.
- Overmolding Processes: Combines cast metal components with additional materials to improve part functionality and performance.
Investment Casting
- Precision Investment Casting: Also known as lost-wax casting, this process produces highly intricate components with tight tolerances and excellent surface finishes.
Sand Casting
- Traditional Sand Casting: Utilizes green sand or Petrobond molds to create cost-effective large and heavy metal components.
- Lost Foam Casting: Uses evaporative foam patterns to produce highly complex geometries that are difficult to achieve with conventional sand casting methods.
Permanent Mold Casting
- Permanent Mold Casting: Uses reusable metal molds to deliver consistent mechanical properties, repeatability, and improved surface quality.
High-Performance Machinery and Tooling
TFG USA supports complex custom metal casting programs through advanced foundry equipment, precision tooling, and tightly controlled production processes designed for repeatable quality and dimensional accuracy.
Advanced Casting Equipment
Our manufacturing partners utilize automated robotic casting cells, high-performance melting furnaces, and precision crucible systems engineered for consistent and efficient production.
Precision Tooling and Mold Design
Hardened steel molds and optimized gating systems are designed to support complex geometries while controlling metal flow, shrinkage rates, and overall part consistency.
Tight Tolerance Control
Careful management of draft angles, parting lines, and porosity reduction allows us to achieve tight tolerances up to +/- 0.005 inches depending on the alloy and casting process.
Broad Part Size Capabilities
Our casting capabilities support everything from lightweight precision housings to large structural metal components weighing several hundred pounds.
Specific Metal Casting Materials We Use
TFG USA sources and casts a diverse range of premium ferrous and non-ferrous metals. We support these materials with complete material certifications verifying exact alloy composition and mechanical properties.
- A380 Aluminum alloy: This industry standard provides an optimal balance of mechanical properties, castability, and heat resistance for structural parts and housings.
- A383 Aluminum alloy: This alloy offers superior resistance to hot cracking and flows efficiently into complex molds, making it ideal for parts with highly intricate details.
- A360 Aluminum alloy: This material delivers maximum pressure tightness and high corrosion resistance, so it’s perfectly suited for fluid-handling and weather-exposed components.
- ADC12 Aluminum alloy: This highly versatile alloy is renowned for excellent machinability and dimensional stability in high-volume production runs.
- Copper and bronze: We select these metals for specialized components requiring excellent electrical conductivity, superior corrosion resistance, and low friction.
- Iron and steel: We cast these heavy-duty metals for industrial applications requiring maximum tensile strength, durability, and wear resistance in demanding environments.
Secondary Processes and Finishing Capabilities
TFG USA supports custom metal casting programs with integrated secondary operations and finishing services designed to simplify supply chains and deliver fully completed components.
Precision Secondary Operations: Our post-casting capabilities include CNC machining, tapping, drilling, and deburring to achieve critical dimensions, tight tolerances, and built-to-print specifications.
Surface Finishing Services: We offer a range of finishing options to improve corrosion resistance, durability, and appearance, including anodizing, plating, and powder coating.
Assembly and Value-Added Services: Complete component assembly and value-added processing help reduce vendor complexity while improving production efficiency and overall project coordination.
Kickstart Your Next Metal Casting Project
Looking for a reliable partner for medium to high-volume metal casting production? Contact TFG USA to discuss your die casting, investment casting, or custom cast metal component requirements with our US-based team.
Frequently Asked Questions
What Do You Mean by Metal Casting?
Metal casting is a foundational manufacturing process where molten metal is poured into a precise mold cavity. The material then cools and solidifies into complex and solid shapes.
The process requires five key steps including pattern making, mold making, melting, pouring, and final extraction. This method allows engineers to create highly detailed parts that would be too difficult or expensive to machine from a solid block.
Is CNC Machining Better Than Metal Casting?
CNC machining is highly precise, but it’s often more expensive and slower at massive scale due to material waste. Metal casting is highly efficient and cost-effective for medium to large volume production runs of complex geometries.
Machining removes material from a solid block, requiring more time per unit during large runs. Casting forms the part directly, and manufacturers typically use CNC machining as a secondary operation to achieve final tight tolerances. This combined approach delivers both scalability and precision for industrial buyers.
What Is the Easiest Metal to Cast?
Aluminum is highly favored for industrial and high-volume production runs. Alloys like A380 and A383 feature a lower melting point and superior resistance to hot cracking.
These materials flow efficiently into complex molds, making them exceptionally castable for industrial structural parts and housings. This reliable flow rate helps manufacturers maintain consistent mechanical properties across massive production runs.
Client Testimonials
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Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
