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Low Pressure Permanent Mold Aluminum Casting

Since 1988, Premier Aluminum LLC has built a reputation as one of the most knowledgeable and trusted names in the aluminum casting industry. Located in Racine, Wisconsin, our foundry has grown to become a leading provider of permanent mold aluminum castings, serving customers across automotive, aerospace, defense, medical, and industrial sectors.

One of the most advanced capabilities we offer is Low Pressure Permanent Mold (LPPM) casting. Unlike traditional gravity casting, this process uses carefully controlled low pressure to fill the mold cavity, resulting in superior metal flow, reduced turbulence, and castings with fewer defects. By incorporating LPPM technology into our fully integrated foundry, Premier Aluminum ensures that customers benefit from improved mechanical properties, higher dimensional accuracy, and a smoother surface finish.

image of a machined permanent mold aluminum casting at Premier Aluminum

Advantages of Our Low Pressure Permanent Mold Casting

At Premier Aluminum, our Low Pressure Permanent Mold Casting process delivers a unique balance of quality, consistency, and performance that other casting methods can’t match. By carefully controlling mold filling under low pressure, we produce aluminum castings with superior density, durability, and dimensional accuracy.

Key advantages include:

  • Superior mechanical properties, with reduced porosity and improved structural integrity.
  • Enhanced surface finish and dimensional precision, minimizing the need for secondary machining.
  • Controlled metal flow and solidification, ensuring uniform casting quality from part to part.
  • Flexibility in production volumes, optimized for low- to medium-run programs.
  • Ability to produce castings from 1 to 125 pounds, from complex geometries to larger structural components.
  • Integration with machining, finishing, leak testing, and assembly, streamlining production and quality control under one roof.

We proudly stand behind our brand promise: High-Quality Castings, High-Level Value. By offering Low Pressure Permanent Mold Casting, Premier Aluminum provides customers with a proven process that bridges the gap between sand casting and die casting — delivering durable, high-performance aluminum parts at competitive costs.

Our Low Pressure Permanent Mold Process

Image of Low Pressure Permanent Mold Process

Metal Preparation & Alloy Selection

Every project begins with proper alloy selection and melt preparation. Premier Aluminum offers a wide range of aluminum alloys, each chosen based on the mechanical, thermal, or corrosion resistance requirements of the application. Careful melt control ensures the highest quality material enters the mold.

Controlled Low Pressure Filling

The hallmark of this process is the use of controlled low pressure to move molten aluminum into the mold cavity. Unlike gravity casting, low pressure filling minimizes turbulence, ensuring smoother flow and uniform distribution. This results in fewer defects, stronger parts, and enhanced repeatability across production runs.

Solidification & Cooling

During solidification, low pressure maintains stability within the mold, producing parts with superior density and reduced porosity. The controlled cooling cycle improves dimensional accuracy, ensuring that the final casting meets tight tolerances.

Machining & Finishing

Once castings are removed from the mold, they move seamlessly to our in-house CNC machining centers and finishing department. With 23 horizontal machining centers, 18 vertical machining centers, and 31 lathe turning centers, we provide precise machining tailored to customer specifications. Finishing options, from coatings and polishing to pressure and helium testing, prepare components for immediate use.

Final Inspection & Delivery

Before any part leaves our facility, it undergoes rigorous quality control. Our capabilities include 4 coordinate measurement machines (CMMs), real-time x-ray inspection, and laser scanning to confirm dimensional accuracy and structural integrity. Leak testing ensures airtight performance when required. Once approved, castings are packaged and delivered as production-ready components.

Industries We Serve

Premier Aluminum’s Low Pressure Permanent Mold Casting serves industries where precision, strength, and reliability are non-negotiable. From aerospace and defense to automotive, medical, and industrial markets, this process provides the consistency and durability needed for mission-critical applications. The industries below highlight just some of the sectors that rely on our advanced casting expertise

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

Why Choose Premier Aluminum?

A Proven Leader

Premier Aluminum is a global leader in permanent mold aluminum castings, recognized for quality and reliability. We specialize in assembly-ready, fully machined aluminum castings that support demanding applications.

Customer-Focused

We are dedicated to long-term relationships, customer satisfaction, and continuous improvement. By working closely with clients, we deliver solutions that are cost-effective, on-time, and aligned with evolving needs.

Specialized Expertise

Our niche lies in producing high-density, high-strength aluminum castings where low- to medium-volume runs require both precision and flexibility. We have extensive experience with complex projects, including heating elements and stainless steel inserts cast into aluminum parts.

Facility & Capabilities

  • Founded in 1988, Racine, WI
  • 9-acre site with a 200,000 sq. ft. foundry, including 4,500 sq. ft. office space
  • 23 Horizontal Machining Centers
  • 18 Vertical Machining Centers
  • 31 Lathe Turning Centers
  • 19 Casting Stations
  • 4 Coordinate Measurement Machines
  • 1 Laser Scan System
  • Extensive melt capacity

With this infrastructure, Premier Aluminum is equipped to deliver not only low pressure permanent mold castings but also complete, production-ready solutions.

When quality, consistency, and efficiency matter, turn to Premier Aluminum LLC for Low Pressure Permanent Mold casting. By combining advanced casting technology with in-house machining, finishing, testing, and assembly, we provide turnkey aluminum solutions for industries that demand the best.

Contact us today to request a quote or speak with one of our Low Pressure Permanent Mold casting experts.

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

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