What’s new at LeClaire Manufacturing? What’s happening in the aluminum casting industry, and what does it mean for your business? Read our blog posts to find out!
Aluminum casting alloys fall into families by their main alloying element, and each family trades strength, castability, and corrosion resistance differently. This hub covers how alloys are designated, the nine alloys LeClaire pours, how to choose between them, and which alloys fit which industries.
Categories: Aluminum Casting, Permanent Mold Casting, Sand Casting
A201 is a silver-bearing aluminum-copper alloy and the highest-strength aluminum alloy commonly sand or permanent mold cast. This guide covers A201 composition, properties by temper, how it compares with A206, where defense and aerospace programs use it, and what to know before sourcing it.
Categories: Aluminum Casting, Permanent Mold Casting, Sand Casting
A206 is a high-strength aluminum-copper casting alloy that can replace ductile iron in many structural parts at well under half the weight. This guide covers A206 composition, T4 and T7 properties, how it compares with A356, why defense programs specify it, and what it takes to cast it well.
Categories: Aluminum Casting, Permanent Mold Casting, Sand Casting
C355 is a high-purity aluminum-silicon-copper-magnesium casting alloy that carries more load than A356 while staying pressure tight. This guide covers C355 composition, properties by temper, how it compares with A356, and the heavy truck and industrial parts it's specified for.
Categories: Aluminum Casting, Permanent Mold Casting, Sand Casting
535 aluminum, also called Almag 35, is an aluminum-magnesium casting alloy that reaches full strength without heat treatment and resists saltwater corrosion. This guide covers 535 composition, properties, corrosion behavior, how it compares with A356 for marine parts, and what to know when sourcing it.
Categories: Aluminum Casting, Permanent Mold Casting, Sand Casting
A357 is a higher-magnesium relative of A356 that reaches higher strength after heat treatment. This guide covers A357 composition and properties, the beryllium-free E357 and F357 variants, how the family compares with A356, and what to know when sourcing these castings.
Categories: Aluminum Casting
A356 is the most widely used aluminum casting alloy for parts that need strength, ductility, and pressure tightness. This pillar guide covers A356 composition, properties by temper and process, heat treatment, alloy comparisons, applications, and how to specify A356 castings.
Categories: Aluminum Casting, Sand Casting
Rising defect rates, missed ship dates, and slow corrective actions are signs it may be time for a new casting supplier. This guide covers the warning signs, a checklist for vetting a new foundry, and a step-by-step plan for transferring tooling.
Categories: Aluminum Casting
Heat treatment turns an as-cast aluminum part into one with the strength, hardness, and stability the application needs. This guide covers the main types of heat treatment, the three-stage cycle for aluminum castings, and how to choose between T4, T5, T6, and T7.
Categories: Aluminum Casting
Cores create the hollow sections and internal passages a mold can't form on its own. This guide covers how sand cores are made, the main core making processes, and what engineers should know about core design and quality.
Categories: Aluminum Casting, Sand Casting
Explains what a single source manufacturing supplier does and the concrete lead time, quality, and accountability advantages of sourcing casting, tooling, and machining from one shop instead of coordinating several vendors.
Categories: Machining
A practical guide to lowering parts-per-million defect rates in sand casting through mold flow simulation, automated process control, in-house core making, and tooling design changes.
Categories: Sand Casting
Covers why heavy truck manufacturers convert parts to aluminum casting, which components are common candidates, and the casting and machining considerations specific to commercial vehicle applications.
Categories: Aluminum Casting
Compares die casting and sand casting across tooling cost, production volume, part size, and design flexibility, helping engineers and buyers decide which process fits a given part.
Categories: Sand Casting
Breaks down the two main types of porosity in sand casting, gas porosity and shrinkage porosity, their specific causes, and the process controls that prevent them.
Categories: Sand Casting
Explains why aluminum resists corrosion in marine environments through its self-forming oxide layer, and covers the alloy selection and casting considerations specific to marine applications.
Categories: Aluminum Casting
Prototype manufacturing turns a design into a functional test part before committing to full-scale production. Here's how the process works, what it's used for, and how it connects to low-volume and full production.
Categories: Machining
Aluminum castings give agricultural equipment a lighter, corrosion-resistant alternative to steel and iron parts. This guide covers where aluminum fits in ag equipment manufacturing and what to consider when converting a part.
Categories: Aluminum Casting
CNC turning rotates a workpiece against a fixed cutting tool to produce precise, rotationally symmetric parts. Here's how the process works, what it's best suited for, and how it differs from milling.
Categories: Machining
CNC milling uses a rotating cutting tool to shape metal parts with tight tolerances. This guide covers how the process works, its advantages, and how it compares to CNC turning.
Categories: Machining
Tool and die manufacturing builds the molds, dies, and fixtures that shape every casting and machined part that follows. This guide covers how the process works, why tooling quality matters, and what to look for in a supplier.
Categories: Machining
Permanent mold casting uses a reusable steel mold instead of disposable sand, producing finer grain structure, roughly 15% higher mechanical properties than comparable sand castings, and molds rated for 50,000-plus cycles. Leading US manufacturers include LeClaire Manufacturing, Stahl Specialty, Alcast Company, Premier Aluminum, Watry Industries, Batesville Products, and Le Sueur Incorporated.
Categories: Permanent Mold Casting
Sand casting is the better choice for large parts, low production volumes, and fast, low-cost tooling; investment casting is the better choice for smaller, complex, thin-walled parts that need tight tolerances (ISO 8062 grades CT4–CT7) and a smooth as-cast surface finish (Ra 1.6–6.3 µm). Sand casting scales to 200-plus tons, while investment casting tops out around 1,000 pounds. If you're specifying a cast metal part and trying to decide between these two processes, the choice comes down to four factors: part size, tolerance requirements, production volume, and budget for tooling versus per-part machining. This guide walks through each factor with real numbers, then breaks down which process fits which use case.
Categories: Sand Casting
Green sand casting is a metal casting process that pours molten metal into a mold made from moist, clay-bonded sand. "Green" refers to the mold being uncured and moist at the time of pouring, not its color. It's the most widely used and lowest-cost sand casting method, well suited to ferrous and non-ferrous alloys alike, though it holds looser tolerances than chemically bonded sand methods. If you're specifying or sourcing a cast metal part and keep seeing "green sand casting" come up, this guide covers how the process actually works, where it's used, and how it stacks up against other sand casting methods. It's written for engineers and procurement teams evaluating casting processes, not for foundry personnel already familiar with the equipment.
Categories: Sand Casting
The strongest US sand casting manufacturers in 2026 combine ISO-certified process control, in-house core making and machining, and real experience in demanding sectors like defense, heavy truck, and off-highway equipment. Leading names include LeClaire Manufacturing, Waupaca Foundry, Consolidated Precision Products, Charlotte Pipe & Foundry, Neenah Foundry, Erie Bronze & Aluminum, Bremen Castings, Badger Alloys, Bunty LLC, Willman Industries, and Le Sueur Incorporated.
Categories: Sand Casting
The leading US aluminum casting manufacturers in 2026 pair deep alloy expertise (200 through 500 series) with tight process control across sand and permanent mold methods. Standouts include LeClaire Manufacturing, Alcast Company, Stahl Specialty, Eck Industries, US Aluminum Castings, Premier Aluminum, CPP-Cudahy, and Le Sueur Incorporated.
Categories: Aluminum Casting
Aluminum casting is one of the most versatile and widely used manufacturing processes across industry. This guide covers what it is, how the main methods compare, what industries rely on it, and what to look for when sourcing a casting supplier.
Categories: Aluminum Casting
The Pressure Equipment Directive sets strict safety and manufacturing standards for components used in pressurized systems. Here is what PED certification requires, what it means for buyers, and why it matters when sourcing aluminum castings for pressure equipment applications.
Categories: Aluminum Casting
ISO 9001 certification is one of the most important quality indicators in manufacturing. Here is what it means, what it requires, and why it matters when selecting an aluminum casting supplier.
Categories: News
ISO 14001 certification signals that a manufacturer manages its environmental responsibilities systematically. Here is what the standard requires, what it means for buyers, and how LeClaire Manufacturing holds this certification across both of its facilities.
If you are looking for efficient, versatile prototyping services, sand casting holds sizable advantages over most other alternatives.
Categories: Sand Casting
Sand casting is among the most versatile and cost-effective casting processes. Learn about how it is done, its strengths and weaknesses, and more.
Categories: Sand Casting
If your business needs precisely cast and machined parts, working with a full-service foundry and machine shop can lead to better communication, efficiency and effectiveness vs. using a separate foundry and machine shop.
Categories: Aluminum Casting, Machining
The uses of sand casting and permanent mold casting would be limited without casting cores, which allow for more complex designs and hollows.
Categories: Aluminum Casting
When planning for a sand casting project it is important to consider what the common defects in sand casting are and have a plan so that you can avoid them.
Categories: Sand Casting
What are some design factors that can help you reduce the cost of your casting project? We have two recommendations that can safely help you reduce the cost of your casting project.
Categories: Aluminum Casting, Machining
The Benefits of Aluminum For Railroad Parts In the rail industry, lower mass results in greater load capacity and reduced fuel consumption. This lower mass and the corrosion-resistant characteristics of aluminum have brought aluminum castings to the forefront of locomotive applications. LeClaire Manufacturing’s ability to make pressure-tight, highly cored, and porosity-free aluminum castings have positioned us as a key supplier to the rail industry.
Categories: Aluminum Casting
The entire team at LeClaire Manufacturing Co. would like to wish you a Happy Holiday! We are grateful for your support and loyalty over this past year. It was a tumultuous one, for sure. We look forward to supplying leaders in the industry with all of their aluminum casting needs.
Categories: Aluminum Casting, News
Manufacturing industries utilize aluminum casting for a variety of reasons. Casting is a relatively simple and cost-effective way of forming a wide array of products. Furthermore, aluminum can be shaped and maneuvered into a variety of products and shapes which is why industries, such as the automobile industry, use this specific metal for much of its production design. In fact, the automobile industry uses cast aluminum for over 50% of its products. Because automobiles are made with intricate engine components, casting is a necessary element to ensure full optimization. However, there are various industries that use aluminum casting because of its versatility and long-lasting elements.
Categories: Aluminum Casting, Permanent Mold Casting
Block castings are traditionally used in the automobile and recreational vehicle industry. To put it simply, the specification of die casting engine blocks are environmentally sound, lightweight, and have high strength and high surface finishing. Because recreational vehicles have become more and more sophisticated with every passing year, manufacturers are constantly looking for methods to enhance the various materials that go into making a quality vehicle. The need to make parts stronger than ever to comply with industry standards means understanding the various casting methods out there.
Categories: Aluminum Casting
At LeClaire Manufacturing, our main goal is to provide quality service and products to our clients. Since our foundry is a one-stop shop for your aluminum casting and machining needs, it is important that our clients are satisfied with our services. Here is what a few of our clients have to say.
Categories: News
LeClaire is your one-stop shop for single-source aluminum casting. Utilizing tool & die, sand casting, permanent mold casting, and machining, our state-of-the-art platforms make us a premiere casting company.LeClaire Manufacturing would like you to join us at The Assembly Show in Rosemont, Illinois from October 26th-October 28th. We will be located at Booth #1643 in the Donald E. Stephens Center.
Categories: News
Metal mold casting has been around for a long time. Metal casting is arguably one of the earliest industrial processes in history. Throughout previous decades, this form of casting has been utilized to make tools, weapons, sculptures, transportation, and various other objects.
Categories: Aluminum Casting, Permanent Mold Casting
Do you want to learn more about die casting benefits? At LeClaire Manufacturing, we understand the aluminum casting process. Learn more here.
Categories: Tool & Die
LeClaire Manufacturing will be exhibiting at the show near the Connection Zone at booth 2099. Because LeClaire is considered a one-stop-shop in the aluminum casting process, buyers and decision-makers alike will have a lot to gain by exploring LeClaire's product categories at the show.
Categories: News
Aluminum is an excellent choice for machining because it is easy to shape. It’s a better choice for many projects because it is more machinable than other metals like steel. Because aluminum is readily available, and easy on equipment as well as cost-effective manufacturers choose aluminum for machining projects. But how do you know what aluminum alloy is the one for your specific project or application?
Categories: Machining
Manufacturing companies have been in the midst of a significant shift for the past few years. Because digitization and internet technology continues to evolve, the way we produce products these days has transitioned into what we are now calling the fourth (industrial) revolution. More specifically, 5G technology will forever change the productivity, efficiency, and timeliness of the manufacturing business.
Categories: News
Both the railroad industry and automotive industry are benefitted from the aluminum casting process. For more information, read this recent blog.
Categories: Aluminum Casting
Let us introduce you to the great people that work at Le Claire Manufacturing! These people work hard to make sure everything runs smoothly for all Le Claire Manufacturing clients!
Categories: News
At its core, CNC machining is used to create parts and components for almost every industry and application. But still, what exactly is CNC manufacturing, and why is it so important in today's technological society?
Categories: Machining
Aluminum Casting provides a service for leading industry manufacturers. This process ensures sustainability and the structuring of a wide variety of products.
Categories: Aluminum Casting
This article briefly summarizes the essentials of the tool and die machinist. If you want to know the basics, click here to learn more.
Categories: Machining, Tool & Die
The die casting process produces items that we use on a daily basis. This specific manufacturing process helps all types of industries. Die castings are among the most mass-produced items in manufacturing today.
Categories: Aluminum Casting, Machining
If you have a large project that you are planning for, sand casting is likely your project's consideration. But should you be considering permanent mold casting instead? Sand casting is an excellent option but can have a higher cost per item cast and a lower production rate. Our foundry focuses on quality regardless of the option you choose. With this in mind, we will review the pros of each option. By reviewing permanent mold casting vs. sand casting you can make an informed decision for your project.
Categories: Permanent Mold Casting, Sand Casting
LeClaire Manufacturing is a family-owned business servicing a wide-array of industries around the world.
Categories: Aluminum Casting, News
Since the dog days of the early 1900's, when Henry Ford was ram-rodding the idea of an "assembly line", while his customers were asking him for "faster horses", OEM's (Original equipment manufacturers) have sought out Machine Shops as their primary source for castings. It made sense, the machine shop was the last stop in the line, so from a material flow standpoint, the OEM buys from the machine shop, and the machine shop sources the castings to a foundry.
Categories: Aluminum Casting, Machining, Permanent Mold Casting
Across all of manufacturing, the question “Which process should I use?” can only be solved by asking and answering further questions about the application at hand, the requirements of the project overall, and your needs as a customer. This is as true for aluminum casting methods as it is for any other process. The benefits and applications of using aluminum casting techniques for a project are vast, but there are several further choices to consider when deciding how to cast aluminum parts for your application.
Categories: Aluminum Casting
Product design tailored to the CNC machining process is one of the easiest ways to lower production costs, yet it is often treated as a cursory consideration during the design process — not the major cost (and time) saving factor that it can be. To be clear, in the early stages of design, unfettered brainstorming and concepting is fine (and even preferable). Though as you fine-tune the product and approach the stage of generating technical drawings to be used for production, it can be extraordinarily helpful to begin incorporating best practices and standards for the CNC machining process.
Categories: Machining
Permanent mold casting refers to the fact that the same mold is used for each casting cycle, rather than being broken away after each use as with sand casting. Although the mold is not truly “permanent” — as with any process and tooling, it will degrade over time and eventually need to be refurbished or replaced — the name applies to the continually used nature of the mold.
Categories: Permanent Mold Casting
With the numerous types of casting and molding available, it can be difficult to know which one to choose for your product. Each process that you might consider will have different pros and cons, which will all play a role in helping you decide which process is the right one for you. This piece will help you make a well-informed decision by understanding the process of sand casting: what it is, what the potential benefits are, and what any potential drawbacks might be.
Categories: Sand Casting
Choosing the right casting process involves considering what the design needs and the economics of each possible route. It’s often an iterative process as casting method influences yields, part design and secondary finishing operations. A better understanding of the strengths of each method helps reduce the number of options and saves time.
Categories: Permanent Mold Casting