Die Casting Market: Automotive Demand, Quality Standards & Industry Expansion

According to IMARC Group's latest research publication, The global die casting market size was valued at USD 73.3 Billion in 2025. Looking forward, IMARC Group estimates the market to reach USD 112.8 Billion by 2034, exhibiting a CAGR of 4.91% during 2026-2034.

How AI is Reshaping the Future of Die Casting Market

• In real time, AI-based machine vision systems can inspect the die castings for porosity or surface cracks, with greater accuracy and lower false rates than humans, preventing parts being rejected after production and increasing process consistency.
• Machine learning algorithms can analyze the temperature, pressure and cycle times from the sensors, and automatically optimize the casting parameters to reduce waste, consume energy and maximize production across multiple machines.
• To minimize breakdowns, increase the lifespan of the machine, and maximize its output, AI systems can predict equipment failures by assessing the state of the equipment.
• Manufacturers are leveraging Internet of Things sensors and AI analytics tools to better understand production availability, use material and machines better, and make equipment across their factories more efficient.
• By using virtual die casting technology, die designs and parameters can be defined through simulations of the die casting process, which allows designers to improve die design while reducing product development time and improving production efficiency.

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Die Casting Industry Overview

Developments in electric vehicles, automation and other manufacturing improvements are affecting the die casting industry. In early-January 2023, General Motors announced it would invest USD 918 million in four of its plants, including USD 55 million in die casting to make electric vehicles. Tesla was the first company to utilize 9,000-ton Giga presses at scale to make parts for the Cybertruck, but Toyota, Hyundai, and Lexus are also building mega-casting facilities. An ultra large die casting machine developed by UBE Machinery, of Japan, in August 2024, also includes a UH9000 9000 metric tons of clamping force, as well as a UH7300 and a UH4500 model.

Die Casting Market Trends & Drivers

• The rise of electric vehicles (EV) is massively reshaping demand for die casting and the need for large, purpose-built die castings including the battery housing, electric motor casing and the body structure integrated into the underbody. Tesla's Model Y uses a 65 kg (143 lb) gigacasting for the rear floor, replacing 171 stamped parts and 1600 welding points. Other automakers are also investing in gigacasting, with Toyota, Hyundai, Nissan, and Honda leading the charge. Toyota anticipates the technology being employed for EVs starting in 2026. Full-size EV underbodies are cast by Chinese supplier Ningbo Haitian in 12,000-ton machines. Chinese supplier LG Energy Solution partnered with Ryobi to cast aluminum die-cast battery enclosures. Aluminum enclosures are 25% lighter than steel and provide better battery temperature control.
• As die casting of aluminum or magnesium becomes more common in the automotive industry, as a result of lightweighting and emissions targets, the industry is increasingly looking to die casting to replace fabricated or stamped steel components, keeping the same structural performance and safety, while reducing weight and emissions. The automotive industry consumes 54.5% of the die casting market, with applications such as transmission cases, engine blocks, engine covers, structural components, and powertrains. In December 2023, the production of motor vehicles in India stood at 5,851,507 units, an increase from the previous year's 5,457,242 units in December 2022, indicating a growing demand for automotive die castings.

Automation, wide automation and data utilization of the die casting production process, smart process control technology, and Industry 4.0 are being applied. In April 2021, Toyota Industries Corporation (TICO) and Siemens agreed to build new artificial intelligence (AI) with which to predict abnormalities in the aluminum die casting process in TC factories that make automotive air conditioning compressors to avoid abnormal situations by monitoring the production status. The application of digital twin technology in the casting systems allows the manufacturers to create a digital model of their casting process and to digitally design molds and dies, reducing the time required to do so by 25%.

Leading Companies Operating in the Global Die Casting Market

• BUVO Castings
• Dynacast
• Endurance Technologies Limited
• FAIST Group
• GF Casting Solutions
• Gibbs Die Casting Corporation
• Linamar Corporation
• Martinrea Honsel
• Nemak
• Pace Industries
• Rockman Industries Ltd
• Ryobi Limited
• Sundaram Clayton Limited

Die Casting Market Report Segmentation

Analysis by Process:

• Pressure Die Casting
• Vacuum Die Casting
• Squeeze Die Casting
• Others

Analysis by Raw Material:

• Aluminum
• Magnesium
• Zinc

Analysis by Application:

• Automobile
• Body Parts
• Engine Parts
• Transmission Parts
• Others
• Heavy Equipment
• Construction
• Farming
• Mining
• Machine Tools
• Plant Machinery
• Chemical Plants
• Petroleum Plants
• Thermal Plants
• Paper
• Textile
• Others
• Municipal Castings
• Valves and Fittings
• Pipes
• Others

Regional Insights:

• North America (United States, Canada)
• Asia Pacific (China, Japan, India, South Korea, Australia, Indonesia, Others)
• Europe (Germany, France, United Kingdom, Italy, Spain, Russia, Others)
• Latin America (Brazil, Mexico, Others)
• Middle East and Africa

Asia Pacific accounted for the largest market share of over 54.3%. Its dominance is fueled by industrialization, growing manufacturing base, and increasing demand for automotive, consumer electronics, and industrial parts.

Recent News and Developments

• August 2024: UBE Machinery Corporation expanded its ultra-large die casting machine lineup, unveiling the UH9000 model with 9,000 metric tons clamping force, alongside new UH7300 (7,300 tons) and UH4500 (4,500 tons) models, providing comprehensive solutions for gigacasting applications across the automotive industry.
• March 2025: Shibaura Machinery announced development of ultra-large die casting machines with clamping forces between 6,000 and 12,000 tons for producing massive automotive underbody gigacastings, targeting annual sales of 10 units across Japan, South Korea, India, and North America markets.
• January 2023: General Motors announced a strategic USD 918 million investment distributed across four manufacturing plants, with USD 55 million specifically allocated for developing electric vehicle die casting component production capabilities and advanced manufacturing technologies.
• First Half 2024: Yizumi achieved revenue of USD 332.7 million representing 20.82% year-on-year growth, with die-casting machines performing exceptionally well at USD 58.5 million in sales revenue, accounting for 17.6% of total sales and demonstrating 35.3% year-on-year increase.
• April 2021: Toyota Industries Corporation partnered with Siemens to develop artificial intelligence that predicts product abnormalities in aluminum die casting for automotive air conditioning compressor production, successfully implementing real-time monitoring to prevent defects and improve quality standards.

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