U.S. Nonferrous Metal Foundry Products Market Size & Share Analysis - Trends, Drivers, Competitive Landscape, and Forecasts (2025

Description

The U.S. nonferrous metal foundry products market reached a valuation of USD 13.5 billion in 2024 and is projected to grow to USD 18.4 billion by 2032, progressing at a steady CAGR of 4.1% from 2025 to 2032. This growth highlights the sector's indispensable role in supporting key U.S. industries, including automotive, aerospace, construction, and electronics.

Nonferrous metals like aluminum, copper, and zinc continue to dominate the market due to their superior conductivity, corrosion resistance, and lightweight properties. These materials are foundational for manufacturing precision engine components, structural assemblies, and large-scale industrial equipment. In an era increasingly shaped by sustainability and innovation, the rise of electric vehicles (EVs) and renewable energy technologies is further enhancing demand for nonferrous metal components across various sectors.

As the U.S. continues to evolve its industrial base, foundries are adapting through innovations in casting technologies and a growing emphasis on environmentally responsible operations. These factors are collectively reshaping supply chains and reinforcing the strategic importance of nonferrous metals in modern manufacturing.

Key Insights

Aluminum remains the dominant metal in the U.S. nonferrous metal foundry products market, accounting for a 65% revenue share in 2024. Its usage is especially prominent in automotive, aerospace, and construction sectors, with applications such as engine blocks and transmission housings.

Magnesium is emerging as the fastest-growing metal category, driven by its increasing adoption in lightweight automotive components aimed at boosting fuel efficiency.

Die casting is the leading casting process in 2024, contributing 60% of market revenue. Known for its high-efficiency and precision, die casting supports mass production of complex parts for automotive and consumer electronics sectors.

Investment casting is the fastest-growing casting technique due to its ability to produce intricate, high-performance parts with minimal waste.

Automotive and transportation lead all application areas, commanding 70% of market revenue in 2024. The rapid rise in EV production is intensifying demand for lightweight, durable cast components to enhance battery performance and reduce vehicle weight.

Aerospace and defense represent the fastest-growing application segment, spurred by demand for specialized, corrosion-resistant components capable of withstanding extreme conditions.

Direct sales dominate the distribution landscape, securing 75% of the 2024 revenue share. This channel allows foundries to provide customized solutions, maintain quality control, and establish long-term industrial partnerships.

Online marketplaces, while still emerging, represent the fastest-growing distribution channel, offering foundries broader exposure and streamlined procurement options.

The Midwest leads all regions, generating 40% of total revenue in 2024. Industrial hubs such as Ohio, Indiana, and Wisconsin benefit from proximity to key manufacturing clients and efficient transportation infrastructure via the Great Lakes waterway system.

The South is the fastest-growing regional market, driven by increasing industrial investments and the rise of EV manufacturing facilities.

The U.S. market remains moderately fragmented, with around 677 companies participating. Leading players such as Howmet Aerospace Inc. and Precision Castparts Corp. maintain strong positions through innovation and strategic investments.

Recent developments underscore ongoing growth and transformation in the industry. In December 2023, Proterial Ltd. announced the sale of Waupaca Foundry Inc. to Monomoy Capital Partners, expected to close in early 2024. Additionally, Waupaca Foundry enhanced its production capabilities in April 2023 with a new horizontal molding line in Wisconsin.

Product Code: 13589

Chapter 1. Research Scope

1.1. Research Objectives
1.2. Market Definition
1.3. Analysis Period
1.4. Market Size Breakdown by Segments
- 1.4.1. Market Size Breakdown, by Metal Type
- 1.4.2. Market Size Breakdown, by Casting Process
- 1.4.3. Market Size Breakdown, by Application
- 1.4.4. Market Size Breakdown, by Distribution Channel
1.5. Market Data Reporting Unit
- 1.5.1. Revenue
1.6. Key Stakeholders

Chapter 2. Research Methodology

2.1. Secondary Research
- 2.1.1. Paid
- 2.1.2. Unpaid
- 2.1.3. P&S Intelligence Database
2.2. Primary Research
2.3. Market Size Estimation
2.4. Data Triangulation
2.5. Currency Conversion Rates
2.6. Assumptions for the Study
2.7. Notes and Caveats

Chapter 3. Executive Summary

Chapter 4. Market Indicators

Chapter 5. Industry Outlook

5.1. Industry Background
5.2. Market Dynamics
- 5.2.1. Trends
- 5.2.2. Drivers
- 5.2.3. Restraints/Challenges
- 5.2.4. Emerging Economies and Key Opportunities
- 5.2.5. Impact Analysis of Drivers/Restraints
5.3. Impact of COVID-19
5.4. Sociopolitical Impact
5.5. Porter's Five Forces Analysis
- 5.5.1. Bargaining Power of Buyers
- 5.5.2. Bargaining Power of Suppliers
- 5.5.3. Threat of New Entrants
- 5.5.4. Intensity of Rivalry
- 5.5.5. Threat of Substitutes
5.6. Innovation and Technology Trends
5.7. Supply Chain and Value Chain Insights
5.8. Economic and Regulatory Impact
5.9. Market Entry Strategies

Chapter 6. Competitive Landscape

6.1. List of Market Players and their Offerings
6.2. Market Share of Key Players (2024)
6.3. Competitive Benchmarking of Key Players
6.4. Product Benchmarking of Key Players
6.5. Recent Strategic Developments by Key Players
6.6. Company Leadership Matrix

Chapter 7. U.S. Market

7.1. Overview
7.2. Market Revenue, by Metal Type (2019-2032)
7.3. Market Revenue, by Casting Process (2019-2032)
7.4. Market Revenue, by Application (2019-2032)
7.5. Market Revenue, by Distribution Channel (2019-2032)
7.6. Market Revenue, by Country (2019-2032)

Chapter 8. Northeast Market

8.1. Overview
8.2. Economic Indicators
8.3. Demographics and Population Insights
8.4. Regional Hotspots
8.5. Growth Drivers
8.6. Challenges and Barriers
8.7. Competitive Strategies
8.8. Emerging Players
8.9. Import/Export Policies
8.10. Compliance Requirements
8.11. Emerging Investment Areas
8.12. Major Ongoing Projects
8.13. Market Size and Forecast
- 8.13.1. Market Revenue, by Metal Type (2019-2032)
- 8.13.2. Market Revenue, by Casting Process (2019-2032)
- 8.13.3. Market Revenue, by Application (2019-2032)
- 8.13.4. Market Revenue, by Distribution Channel (2019-2032)

Chapter 9. Midwest Market

9.1. Overview
9.2. Economic Indicators
9.3. Demographics and Population Insights
9.4. Regional Hotspots
9.5. Growth Drivers
9.6. Challenges and Barriers
9.7. Competitive Strategies
9.8. Emerging Players
9.9. Import/Export Policies
9.10. Compliance Requirements
9.11. Emerging Investment Areas
9.12. Major Ongoing Projects
9.13. Market Size and Forecast
- 9.13.1. Market Revenue, by Metal Type (2019-2032)
- 9.13.2. Market Revenue, by Casting Process (2019-2032)
- 9.13.3. Market Revenue, by Application (2019-2032)
- 9.13.4. Market Revenue, by Distribution Channel (2019-2032)

Chapter 10. West Market

10.1. Overview
10.2. Economic Indicators
10.3. Demographics and Population Insights
10.4. Regional Hotspots
10.5. Growth Drivers
10.6. Challenges and Barriers
10.7. Competitive Strategies
10.8. Emerging Players
10.9. Import/Export Policies
10.10. Compliance Requirements
10.11. Emerging Investment Areas
10.12. Major Ongoing Projects
10.13. Market Size and Forecast
- 10.13.1. Market Revenue, by Metal Type (2019-2032)
- 10.13.2. Market Revenue, by Casting Process (2019-2032)
- 10.13.3. Market Revenue, by Application (2019-2032)
- 10.13.4. Market Revenue, by Distribution Channel (2019-2032)

Chapter 11. South Market

11.1. Overview
11.2. Economic Indicators
11.3. Demographics and Population Insights
11.4. Regional Hotspots
11.5. Growth Drivers
11.6. Challenges and Barriers
11.7. Competitive Strategies
11.8. Emerging Players
11.9. Import/Export Policies
11.10. Compliance Requirements
11.11. Emerging Investment Areas
11.12. Major Ongoing Projects
11.13. Market Size and Forecast
- 11.13.1. Market Revenue, by Metal Type (2019-2032)
- 11.13.2. Market Revenue, by Casting Process (2019-2032)
- 11.13.3. Market Revenue, by Application (2019-2032)
- 11.13.4. Market Revenue, by Distribution Channel (2019-2032)

Chapter 12. Company Profiles

Chapter 13. Appendix

13.1. Sources and References
13.2. Related Reports

U.S. Nonferrous Metal Foundry Products Market Size & Share Analysis - Trends, Drivers, Competitive Landscape, and Forecasts (2025 - 2032)