Bob Kowalczyk
President & Founder

As a die casting engineer with more than 35 years of experience in prototype and low volume casting production, I have a deep appreciation and understanding of the challenges you, as a designer, face.

Every Prototype casting is critical

Every day at Aluma Cast is unique as we put our skills to work to cast prototypes that meet stringent and varied requirements.

The way we see it, the importance of a prototype is truly immeasurable. A career, a brand name or a company’s reputation may hang in the balance. Prototypes play a critical role in ensuring the quality of the production castings, ensuring no surprises. Whether a casting is small or large, thin wall or robust, simple or complex, requires secondary operations or special documentation, has mating parts or critical mechanical characteristics—whatever the criteria, you can rest assured that at Aluma Cast Foundry your part will receive all the attention and expertise necessary to secure a successful outcome.

Technological advancements in secondary machining capabilities have increased the demand for finished prototype castings to reflect more closely the final production part. We offer turnkey services that give our customers a part that not only looks and feels like the die cast production part, but also performs like it. Turnkey service can save time and money, as well as the aggravation of trying to coordinate different secondary operations. This can include heat treating, machining, inspections, certifications, detailed documentation, painting/coating and partial or full assembly.


Thin Wall Aluminum Prototype Castings

Aluma Cast Foundry

Thin-wall prototype castings can present a challenge in the prototype casting world, but that does not mean that thin-wall parts cannot be cast and properly tested in the prototyping processes. The engineer should never be asked to revise the design of the part to accommodate the limitations of a selected prototyping process. Instead of changing the design to meet prototype process limitations, we recommend working with a prototype process that can produce prototype castings that truly reflect the performance characteristics of the die cast production process.

Complex Geometries Prototype Castings

Aluma Cast Foundry

The Aluma Cast process supports undercuts advantageous for casting prototype parts with complex geometries. It facilitates cooling and/or heating elements to be cast in place. We produce complex castings with secondary services to provide our customers with a part to examine, test or assemble.

Special Needs Prototype Castings

Aluma Cast Foundry

Tell us about your out of the ordinary requirements for your prototype casting project. We master new challenges every day. Whether it’s size, complexity or any other unique critical factor, we are ready to help you find a satisfactory solution.

Low Volume Production

Aluma Cast Foundry

What can you do when your production tooling is no longer usable? You only need a couple hundred parts, but your die casting die or permanent mold is no longer available. Aluma Cast’s low volume casting process may be a viable option for you.

Aluma Cast offers a unique blend of artistry in metals and engineering expertise. The result is a deep appreciation and understanding of the designer’s work and the challenges he faces. Knowing that design changes are integral to the design/prototyping process, we make every effort to work with you to allow for changes ensure a successful end product.

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