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Wisconsin Aluminum Casting Manufacturers

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When manufacturers across Wisconsin need reliable, precision aluminum castings, they turn to proven foundry partners with the experience and capabilities to deliver consistent results. Since 1988, Premier Aluminum LLC has been one of the most trusted aluminum casting manufacturers in Wisconsin, supporting OEMs and industrial manufacturers from our Racine, Wisconsin facility.

As a U.S.-based aluminum foundry specializing in permanent mold casting, Premier Aluminum produces high-quality aluminum components engineered for strength, dimensional accuracy, and repeatability. By combining advanced casting processes with in-house machining, finishing, testing, and assembly, we deliver fully integrated aluminum casting solutions that meet demanding production requirements.

From structural components to precision housings, our aluminum castings support performance-driven applications across a wide range of industries throughout Wisconsin and the Midwest.

Advantages of Aluminum Castings

Aluminum is one of the most widely used materials in modern manufacturing due to its performance characteristics and versatility. Key advantages include:

  • Lightweight strength, supporting durable components without excess mass
  • Excellent corrosion resistance for long service life
  • Dimensional stability for consistent part accuracy
  • Thermal and electrical conductivity for functional applications
  • Design flexibility for complex geometries and integrated features
  • Cost efficiency for low- to medium-volume production
  • Sustainability as a 100% recyclable material

These benefits make aluminum an ideal choice for manufacturers seeking reliable, high-performance cast components.

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Premier Aluminum’s Casting Capabilities

Permanent Mold Casting

Premier Aluminum specializes in permanent mold aluminum casting, producing dense, uniform components with excellent surface finish and repeatability. Controlled mold filling and solidification result in dimensionally stable parts ideal for structural, mechanical, and precision applications.

Semi Permanent Mold Casting

Semi permanent mold casting combines reusable metal molds with sand cores, allowing for more complex internal geometries while maintaining strength and consistency. This process supports lightweight designs, internal passages, and reinforced features commonly required in advanced manufacturing applications.

CNC Machining

Our Racine, WI facility operates more than 70 CNC machining centers, including horizontal, vertical, and lathe turning systems. Integrated CNC machining allows us to achieve tight tolerances, precision bores, threaded features, and complex profiles directly from cast aluminum components.

Tooling & Engineering Support

Premier Aluminum’s in-house tooling and engineering teams work closely with customers from concept through production. Early collaboration helps optimize designs for castability, machinability, and cost efficiency while reducing lead times.

Testing & Quality Assurance

We maintain rigorous quality standards through advanced inspection and testing, including helium leak testing, pressure decay testing, x-ray inspection, CMM inspection, and laser scanning. These processes ensure consistent quality and structural integrity across production runs.

Finishing & Coatings

We offer a complete range of finishing services, including anodizing, chromate, powder coating, plating, polishing, and passivation. These finishes enhance corrosion resistance, appearance, and functional performance.

Full Service Assembly

Premier Aluminum provides full service assembly for customers seeking turnkey solutions. By combining casting, machining, finishing, and assembly under one roof, we simplify supply chains and reduce overall production time.

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Common Aluminum Cast Components

As one of Wisconsin’s leading aluminum casting manufacturers, Premier Aluminum produces a wide range of components, including:

  • Structural frames and supports
  • Housings and enclosures
  • Brackets and mounting components
  • Gear and transmission housings
  • Motor and actuator housings
  • Electronic and thermal management components
  • Machined and assembled subcomponents

Each component is engineered for durability, dimensional accuracy, and repeatable performance.

Industries We Serve

Premier Aluminum supports manufacturers across numerous industries that rely on precision aluminum castings. Our cross-industry experience allows us to apply proven foundry practices and engineering expertise to every project we produce.

  • Food & Beverage
  • Construction
  • Transportation
  • Furniture
  • Medical
  • Electrical
  • Military
  • Robotics & Machine Tools
  • Turf Care
  • TV, Radio & Cable
  • Conveyor & Processing
  • Gasoline Dispensing

Why Choose Premier Aluminum?

Proven Expertise

With more than 35 years of experience, Premier Aluminum is a trusted aluminum casting manufacturer serving customers throughout Wisconsin and beyond.

Integrated Manufacturing Model

Our vertically integrated operations combine casting, CNC machining, finishing, testing, and assembly to ensure consistent quality and reliable delivery.

Engineering Collaboration

We partner directly with OEMs and design engineers to develop cost-effective aluminum casting solutions optimized for performance and manufacturability.

Facility & Equipment

Our Racine, WI facility includes:

  • 23 Horizontal Machining Centers
  • 18 Vertical Machining Centers
  • 31 Lathe Turning Centers
  • 19 Casting Stations
  • 4 Coordinate Measuring Machines
  • 1 Laser Scan System
  • Extensive melt capacity

This advanced infrastructure supports complex aluminum casting and machining programs with repeatable accuracy.

Metalworking processes can involve exposure to fluids used for cooling, lubrication, and machining operations, making proper workplace controls important for manufacturers. The Occupational Safety and Health Administration provides guidance on metalworking fluids to help employers manage potential occupational exposure and maintain safer working conditions.

U.S.-Based Manufacturing

Located on a 9-acre site with a 200,000 sq. ft. foundry and 4,500 sq. ft. office, Premier Aluminum delivers American-made quality backed by decades of manufacturing excellence.

When quality, consistency, and reliability matter, trust Premier Aluminum LLC as your aluminum casting manufacturer in Wisconsin. Our permanent mold expertise, advanced machining, and integrated manufacturing approach deliver results you can depend on.

Contact us today to request a quote or discuss your aluminum casting project.

Phone: 262-685-1995
 Address: 3633 S Memorial Dr, Racine, WI 53403
 Website: www.premieraluminum.com

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