• Elkcast Aluminum, Inc.

    Specializing in small runs with quick turnaround time.

    Established in 1975.

About us

Hours: 6:00 AM - 4:00 PM | Monday - Friday

We are an Aluminum foundry located in Southeastern Wisconsin. We use 3 different types of processes: Green Sand Molding, Air-Set Molding & Permanent Machine Molding. We specialize in castings weighing up to 80 lbs. We use several different types of metal, depending on the job specifications, such as #319 Aluminum, #356 Aluminum, #535 Al-mag & #735 Tenzalloy. Other Alloys can be used upon request.

We pride ourselves on being a "one-stop-shop" for all your aluminum casting needs. We can take care of it all for you. From design to pattern making to producing a raw casting and all the final finishing you may need. We do all our own stainless steel shot blasting in-house and all the machining on your raw casting is done in-house as well. We work with many vendors to give you the completed casting you desire; such as a heat treater, impregnator, powder coater, pattern maker and more.

We currently produce castings for the flagpole industry, railroad industry, lighting industry, trucking industry, boat industry as well as cast various brackets, bearing housings, traffic counter boxes & much more.

We are committed to producing quality parts at an affordable price along with superior customer satisfaction. Give us a call or send us an email to find out what we can do for your company and how much you could be saving with Elkcast Aluminum.

Types of metal we use:

Capabilities


Green Sand

The most cost effective method of casting for low volume, it is done using our Green Sand Squeezer machine.

Air-set Sand

Air set Sand provides a disposable sand that hardens over time around the pattern. This process allows us to produce larger molds with deep draws.

Design

We can assist you in the the development of your product blueprints, to product and pattern design.

Pattern Making

We work closely with a pattern shop to produce a pattern for your casting requirements.

CNC Machining

Done to acheieve extreme precision, the machining is done by programming the computer, telling it where and what to do.

Stainless Steel Shot Blasting

Can be done to remove any sand and small burs. Results in a brighter and more consistant finish.

Heat Treating

Used to harden or soften the material. It also is done to achieve better maching results.

Impregnating

The product is placed in a vacuum, then the micropores get filled with a resin to prevent leaks, reduce moisture entrapment, and improve the integrity of welds.

Powder Coating

Used to create a hard finish that is thicker and tougher than conventional paint.

Plastisol Coating

Provides a tough, grippy coating that also helps resist corrosion, electricity, and abrasion.

Machined Complete

We can do some machining in house, bigger jobs can be outsourced.

Other services available upon request.

Our Facility

What to know before ordering:

  • We will deliver with our own truck locally for a small flat rate, or we will ship using your carrier of choice
  • Order quantities can range from 1 - 25,000 pieces
  • The casting weights can range from 1/4 oz up to 80 lbs
  • The maximum dimensions for castings with Green Sand is: 12 x 24 in or 18 x 18 in
  • The maximum dimensions for castings with Air Set Line is: 60 x Any