Aluminium die casting · Satara, India · Since 2009
Aluminium die castings, machined and ready to fit.
High pressure and gravity die casting, CNC machining and finishing for OEMs and Tier-1 manufacturers. From development batches to recurring production, we supply castings and machined components from Satara, India.
Attach your drawing in your email app and include the quantity and critical requirements. An engineer replies within 24 hours with a quotation or clarification questions.
What we make, and the limits we work to
Can we make your part? Start with the envelope.
The figures below are what our plant runs today. If your part sits near an edge, send the drawing and we will tell you plainly whether it fits.
| Process | Equipment | Part weight | Wall thickness | Alloys | Best suited to |
|---|---|---|---|---|---|
| High pressure die casting | 7 cold-chamber machines: 80, 135, 160, 280, 500, 1,000 and 1,250 t | 20 g – 15 kg | 1.2 – 8 mm | ADC12, ADC10, LM2, LM6, LM9, LM13, LM20, LM24, AlSi-132 | Thin-walled, complex housings and covers at volume |
| Gravity die casting | Tilting and horizontal machines, dies up to 450 × 600 mm | 200 g – 25 kg | 3 – 15 mm | LM4, LM6, LM9, LM13, LM25 | Thicker, structural and pressure-tight parts at low to medium volume |
| Machining & finishing | 6 in-house CNC and VMC machines, plus a long-standing partner with Haas 4th-axis CNC; multi-head drilling and tapping; 7-tank ultrasonic cleaning; 4 shot blast units; powder coating and plating through a long-standing partner | Matched to the casting | — | Supplying finished, ready-to-fit parts with one quality record | |
| Low pressure die casting In development | 20,000 sq.ft plant secured; machines under negotiation | To be published when commissioned | Dense, structural parts such as housings and manifolds | ||
Machine choice depends on projected area, geometry and gating, which we confirm at quotation. Customer-specific alloys can be arranged. Full machine list, crane capacity and capacity answers are on the capabilities page.
Evaluate Alcast for your project
The information your team needs, in one place
Can we make your part?
Check process limits, alloys, machine capacity and machining. Compare your part with the component gallery.
View current capabilities →What is needed for a useful quotation?
Drawing revision, quantity, tooling status and delivery needs help us review scope and explain the next steps.
See the enquiry checklist →How will quality be demonstrated?
Review inspection, traceability and approval documentation. Request the ISO certificate and discuss your PPAP or FAI requirements.
Review quality & documentation →Industries
Where our castings go to work
Most of what we make sits inside motors, pumps, machines and vehicles built by other manufacturers. These are the industries we already supply.
Electric motors & power equipment
End shields, motor covers, terminal boxes, alternator fans, coil wedges
Motors & power →
Pumps & compressors
Pump bodies, lub oil pump housings, pistons, connecting rods, cylinder head covers
Pumps & compressors →
Industrial machinery
Housings, bearing blocks, brackets, levers; agriculture, textile and construction equipment
Industrial machinery →
Automotive, two-wheeler & EV
Crankcases, CVT covers, timing covers, battery enclosure halves
Automotive & EV →
Lighting & thermal management
LED high-bay and floodlight housings, heat sinks, rectifier heat sinks
Lighting & thermal →
Other industries
Agriculture, textile and construction equipment, instrumentation enclosures and valve actuators
All industries →One plant, one quality record
Melt to dispatch, with one point of accountability
Casting quality is decided in the furnace and confirmed at the gauge. We cast, machine, finish and inspect in-house, with specialist partners for selected operations. Alcast coordinates your requirements and keeps records that trace each part back to its melt.
Verified metal
- Spectrometer analysis of every alloy batch
- Electric resistance melting and holding furnaces
- Rotary degassing, checked by density index
Controlled process
- HPDC from 80 to 1,250 t, plus gravity die casting
- Process parameters recorded per tool
- First article inspection on every new tool
Machined and finished
- CNC turning and VMC milling; 4th-axis work with a long-standing partner
- Multi-head drilling and tapping
- 7-tank ultrasonic cleaning and shot blasting; powder coating and plating with a long-standing partner
Checked, packed, traced
- 100% visual inspection; 100% air gauging of critical dimensions
- In-house X-ray
- Export packing and packing audit
Repeat production
Part 10,000 should measure like part one
Recorded parameters, the same die on the same machine, and 100% air gauging of critical dimensions keep a recurring schedule consistent from batch to batch.
How we control qualityFor supplier quality and sourcing teams
Documentation that supports supplier approval
New parts follow an APQP plan from the first design review. We document approval to the level your industry expects and keep records you can audit.
- PPAPAIAG, level 3 by default
- ISIR / FAIFor European and general industry approvals
- PFMEA & control planDeveloped before tooling is released
- Process flow diagramMelt to dispatch, per part number
- Material test certificateSpectrometer results, every batch
- Inspection reportsDimensional layout at 20 °C reference
New parts and tool proving
From drawing to approved production
We review your 3D data for manufacturability before steel is cut, coordinate die build with trusted toolmakers, and sample on the production machine that will run your part. Tool makers and R&D teams can also book T0 trials on our 500, 1,000 and 1,250 t machines from 25 pieces.
Your tooling stays your property, and your drawings stay confidential under NDA.
- 1 · Enquiry & DFMFeasibility, process choice, design feedback
- 2 · APQP planProcess flow, PFMEA, control plan
- 3 · ToolingDie design support, built with partners. Typically 6–10 weeks, depending on die size and complexity; 2–4 weeks for some simpler tools
- 4 · Sampling & PPAPTrial shots, layout, approval, then series production
Who we supply
Quietly, for a long time
We do not publish customer names. Most of our work sits inside someone else’s product, and that is their announcement to make. What we can tell you:
Export
Buying from the UK, Europe or the USA?
We ship machined, finished and documented castings overseas, with the paperwork your market needs: origin documents under the India–UK trade agreement, CBAM production data, PPAP or ISIR.
India–UK CETA in force since 15 July 2026. LM and EN alloys, UK CBAM data support.
For UK buyers → European UnionEN AC alloys, ISIR approval and CBAM production data for EU importers.
For European buyers → United StatesA380 and 383 alloys, AIAG PPAP, landed-cost support and a US phone line.
For US buyers →Where we are investing
Capacity being added
Listed so you can plan with us. None of these is offered until it is commissioned.
Looking ahead: defence manufacturing
We are ready to explore supplying aluminium castings to India’s defence manufacturing base, and are preparing our systems for it. We do not supply defence customers today.
Engineering guides
Answers before you ask
Written by our engineers for buyers and design teams: choosing a process, specifying a part, tooling cost, approval and sourcing from India.
How to write an RFQ for die castings that gets an accurate quote
The ten things a die caster needs to quote accurately, and what to send if your design is not final yet.
Read the guide → Process selectionHPDC vs gravity die casting: which process suits your part?
Wall thickness, tolerance, tooling cost, volume and pressure-tightness compared.
Read the guide → Export sourcingSourcing aluminium die castings from India
Supplier checks, realistic timelines, freight and Incoterms, duties and quality at a distance.
Read the guide →Have a drawing? Send it with your annual volume and we will tell you what it takes to make it.
Direct line
Email the drawing. Talk to the engineer.
Email your drawing for a quote; call or WhatsApp for a quick answer.
The same engineering team replies within 24 hours.
Save contact cardCompany profile (PDF)Registering us as a vendor? Ask for our ISO certificate, company details and NDA by email.