As aerospace and defense demand lighter, stronger, and more complex parts, die casting manufacturers are rising to the challenge. In 2025, the drive for fuel efficiency, advanced materials, and precision is pushing these companies beyond traditional markets into aviation and defense.
The following eight companies are leading this shift, bringing innovation and capacity to serve the high-performance requirements of the aerospace and defense industries.
Dynacast International (USA)
Dynacast has made significant inroads into aerospace and defense by leveraging its precision zinc and aluminum die casting technologies. With decades of experience in miniature components, the company now supplies structural and internal parts for avionics systems, radar housings, and missile guidance components. Its global manufacturing footprint and expertise in complex geometries give it a strong edge in aerospace contracts.
Key Focus:
- Lightweight, high-strength zinc-aluminum alloys.
- Multi-slide die casting for aerospace electronics.
- AS9100-certified facilities.
GF Casting Solutions (Switzerland)
Part of Georg Fischer AG, GF Casting Solutions has been actively expanding into aerospace and defense through its high-pressure aluminum and magnesium die casting processes. It offers lightweight solutions for airframe structures, turbine housings, and UAV components. The company’s European and Chinese facilities provide scalable, cross-regional production for defense primes and commercial aircraft programs.
Key Focus:
- Magnesium die casting for ultra-lightweight parts.
- Integration of additive manufacturing and topology optimization.
- Collaboration with European aerospace OEMs.
Nemak (Mexico)
Known primarily for its automotive casting capabilities, Nemak has invested in high-strength aluminum die casting lines tailored for aerospace components. It now supplies engine housings, satellite brackets, and structural frames for commercial and military aircraft. The company’s move into aerospace is supported by its deep knowledge of metallurgy and automated mass production.
Key Focus:
- Thin-wall aluminum casting for aircraft frames.
- Thermal management components for defense electronics.
- Expansion into North American aerospace hubs.
Ryobi Die Casting (Japan)
Ryobi has broadened its portfolio to include aerospace-grade die castings. Traditionally strong in automotive parts, the company now produces critical components for aircraft HVAC systems, defense communications equipment, and lightweight frame reinforcements. With high-quality finishing and corrosion resistance, Ryobi’s die-cast parts meet rigorous aerospace requirements.
Key Focus:
- Surface treatment and anodizing for aerospace durability.
- Defense electronics housing.
- Investment in AS-certified aerospace foundries.
Gibbs Die Casting (USA)
Gibbs has established itself as a major supplier of aluminum die castings for aerospace-grade electronics, fuel systems, and drone components. The company’s precision machining, vacuum die casting, and X-ray quality control have enabled it to secure contracts with Tier 1 aerospace suppliers.
Key Focus:
- Vacuum die casting for porosity-free critical parts.
- CNC post-processing for avionics components.
- Defense-grade testing and traceability systems.
Endurance Technologies (India)
Endurance Technologies has strategically diversified into aerospace castings, offering aluminum die cast components for aircraft interiors, satellite housings, and surveillance systems. Leveraging its scale in two-wheeler and automotive parts, it has adopted advanced casting simulations and cleanroom assembly to meet aerospace standards.
Key Focus:
- Complex geometries for aerospace interiors.
- AS9100 certification and cleanroom facilities.
- Joint ventures to supply Indian defense initiatives.
Martinrea Honsel (Germany)
Martinrea Honsel has extended its aluminum die casting capabilities to support aerospace and military-grade engine parts. With a history of innovation in structural automotive parts, the company now delivers precision cast housings and lightweight substructures for aircraft and armored systems.
Key Focus:
- Structural aerospace applications.
- Low-porosity casting for high-strength performance.
- Military-grade corrosion-resistant coatings.
Boberry (China)
Boberry, a rising name in China’s precision manufacturing sector, has entered the aerospace and defense arena with advanced aluminum and zinc die castings. Known for its flexibility, tool design, and precision machining, Boberry now supplies high-tolerance parts for avionics, radar systems, and UAVs.
Key Focus:
- Small-batch, high-precision die casting for military electronics.
- Multi-cavity tooling and custom prototyping.
- Strict dimensional control for aerospace component integrity.
Company Comparison Table
| Company | Country | Material Focus | Aerospace Applications |
| Dynacast International | USA | Zinc, Aluminum | Avionics, Radar, Missiles |
| GF Casting Solutions | Switzerland | Magnesium, Aluminum | Airframes, Turbines, UAVs |
| Nemak | Mexico | High-strength Aluminum | Satellite parts, Frames, Thermal housings |
| Ryobi Die Casting | Japan | Aluminum | Aircraft HVAC, Defense electronics |
| Gibbs Die Casting | USA | Aluminum | Avionics, Drone systems, Fuel systems |
| Endurance Technologies | India | Aluminum | Interiors, Satellites, Surveillance gear |
| Martinrea Honsel | Germany | Aluminum | Aircraft engines, Armored vehicles |
| Boberry | China | Zinc, Aluminum | UAVs, Radar, Communication systems |
Market Outlook
The aerospace and defense industries are undergoing rapid transformation, and die casting manufacturers are playing a vital role in supplying lightweight, high-strength, and precision-engineered components. Key drivers shaping the market include:
Demand for Lightweight and Complex Structures
As commercial and military aircraft strive for fuel efficiency and payload optimization, lightweight aluminum and magnesium die castings are in high demand. UAVs, satellites, and next-gen aircraft all require intricate, weight-sensitive parts that die casting excels at producing.
Rising Global Defense Budgets
Geopolitical tensions are pushing governments to increase investment in defense systems, surveillance infrastructure, and aerospace readiness. Die casting manufacturers aligned with military programs will benefit from long-term, high-value contracts.
Innovation in Materials and Simulation Tools
Companies are integrating digital twin simulations, vacuum die casting, and hybrid manufacturing to meet aerospace standards. AM (Additive Manufacturing) is also being paired with traditional casting for complex geometry prototyping.
Regional Shifts and Localization
While the U.S. and Europe remain core markets, India and China are expanding their aerospace capabilities. Boberry’s success reflects China’s efforts to support strategic self-reliance in aerospace technology through localized precision manufacturing.
Projected Market Growth (Global Aerospace & Defense Die Casting):
| Year | Estimated Market Size (USD Billion) | Growth Rate |
| 2025 | 4.8 | — |
| 2026 | 5.3 | 10.4% |
| 2027 | 6.0 | 13.2% |
| 2028 | 6.7 | 11.7% |
| 2029 | 7.6 | 13.4% |
| 2030 | 8.5+ | >12% CAGR |