Aluminum Foundry Serving the United States

Aluminum foundry casting and finishing services

If your part has to fit, ship, and repeat, you do not need another vendor. You need an aluminum foundry that can control the variables that cause scrap, rework, and schedule slips.

Buffalo Metal Casting has produced non-ferrous castings and finished components since 1975, supporting customers across the United States as a single-source supplier from pattern to shipped part.

Request a Quote Talk Through a Part

Capabilities at a Glance

Processes: green sand, no-bake (air-set), precision shell, permanent mold
Alloys: 319, C355, A356, D712, ZA8, ZA12
Size range: ounces to 1,000 lbs
Value-add: machining, heat treat, NDT, finishing, welding, assembly

What “Single-Source Aluminum Foundry” Means Here

More control, fewer handoffs: casting, machining, inspection, and secondary services coordinated under one roof.
Fewer surprises: realistic lead times, clear communication, and quality checks that match how parts get used.
Less vendor juggling: one quote, one schedule, one accountable team.

Aluminum Casting Processes Built Around Your Part

Different geometries and volumes need different methods. We help match the process to your tolerances, finish requirements, and run size.

Permanent Mold Aluminum Casting

Reusable metal tooling for repeat production and consistent results.

Best for: recurring parts, stable dimensions across runs, long-term cost control.

Green Sand Aluminum Casting

Cost-effective molding for small to medium castings where speed and practicality matter.

Best for: production-friendly shapes, balanced cost, straightforward geometry.

No-Bake (Air-Set) Sand Aluminum Casting

A strong fit for larger or more complex castings with improved finish vs typical green sand.

Best for: larger parts, cored designs, higher surface-finish expectations.

Precision Shell Sand Casting

Higher accuracy and a cleaner finish for small to medium castings.

Best for: tighter requirements, cleaner surfaces, repeatable detail.

Automated Flaskless Matchplate Molding

Automated green sand molding for detailed features and repeatability on production work.

Best for: repeat production, consistent results, detailed features.

Aluminum Alloys We Regularly Pour

Aluminum: 319, C355, A356, D712
Zinc Aluminum: ZA8, ZA12

Need something outside this list? Send the spec and application details and we will confirm feasibility.

Capacity Range That Covers Prototypes Through Production

Castings are available from ounces up to 1,000 lbs. Complicated castings with internal geometry are a specialty, including cored designs where process discipline is the difference between “works” and “works every time.”

Quality and Inspection That Protect Your Downstream Work

Rejected parts are expensive. Our Quality Assurance Plan is built to reduce rework by defining procedures across departments, documenting inspections, and aligning to ISO-based expectations.

ISO-aligned quality planning with documented tests and inspections
Inspection and testing support for customer specifications
Non-destructive testing options: X-ray, penetrant, pressure testing
Physical and chemical analysis available when required

Value-Added Services That Turn a Casting Into a Finished Part

If your team is buying a component, not a raw casting, this is where schedules get won or lost. We support “ready for assembly” needs with services that keep quality and timing under control.

Engineering assistance and casting layout support
Pattern-making and production tooling construction
In-house heat treating
CNC machining (vertical milling centers and lathe work)
Finishing: anodizing, plating, painting
Heli-arc welding and assembly

Typical Aluminum Foundry Work We Support

Housings, covers, brackets, and structural components
Cored parts with internal passages or complex geometry
Machined castings that must hit critical dimensions
Projects that need a single supplier from tooling through finished component

Want a Quote That Comes Back Fast (and Accurate)?

Send what you have. If anything is missing, we will tell you exactly what we need.

Print and/or 3D model (STEP preferred)
Target alloy (or performance requirements if flexible)
Annual volume and expected order cadence
Machining requirements (critical dims, datums, threads)
Finish requirements (anodize, paint, plating) if applicable
Any inspection or test requirements (pressure test, NDT, cert needs)

Aluminum Casting Foundry Partner for Customers Across the United States

If you want fewer emails, fewer vendors, and more parts that show up ready to use, let’s look at your part and your timeline.

Request a Quote or Contact Us