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North American Investment Casting Performance and Outlook

By Tim Sullivan, Executive Director, and Merrin Muxlow, Partnerships and Marketing Director, Investment Casting Institute

Lesedauer: min | Bildquelle: Investment Casting Institute

Executive Summary

The North American investment casting market enters 2025 with momentum. Production rose across nearly all end-use sectors in 2024, and most foundries are reporting production gains across key sectors including aerospace, industrial gas turbines (IGT), automotive, and general industry.

That said, the picture isn’t without complexity. While macroeconomic uncertainty, persistent supply chain friction, and a gradually improving labor pool continue to present operational challenges, the overall picture is one of expansion.

Aerospace remains the industry’s anchor—accounting for 60% to 70% of total market volume—while IGT and automotive continue to evolve with technology and policy shifts. Defense casting demand is strong, boosted by foreign military sales and increased national spending.

Aerospace and Defense

Aerospace & Defense continues to be the dominant segment, accounting for an estimated 60% to 70% of the total market. Aircraft production growth continues to fuel demand for precision components. Overall activity in aerospace-related castings increased nearly 25% in 2024.

Passenger traffic metrics confirm a strong rebound: Revenue Passenger Miles (RPMs) rose 4.7% in 2024 despite higher ticket prices and cost-of-living increases. While RPM CAGR from 2012–2024 sat at 17.5%, that pace is expected to cool to a more sustainable 4.7%  through 2026.  Airlines are extending aircraft life due to long OEM delivery backlogs, which are straining manufacturers. Boeing is navigating workforce reductions while ramping up 737 and 787 production; Airbus faces the challenge of tripling A220 and A350 output.

Commercial aerospace continues to lead all end-use sectors. Passenger demand has rebounded strongly, with Revenue Passenger Miles (RPMs) rising 4.7% in 2024, despite inflationary pressures. The compound annual growth rate (CAGR) for RPMs from 2012 to 2024 was 17.5%, though it is forecast to slow to 4.7% from 2024 to 2026.

Airlines are extending aircraft life cycles as OEMs face backlog constraints. Boeing is balancing staff reductions with increased output of the 737 and 787 programs. Airbus, meanwhile, is under pressure to triple production of A220 and A350 units in the coming years.

Defense spending from 2022–2024 marked the third-largest increase since the Cold War, fueled by the conflict in Ukraine and Middle East tensions. U.S. foreign military sales rose from $114 billion to $191 billion in the past five years, even as domestic defense budgets remained flat at around $170 billion. Uncertainty remains around U.S.- European cooperation and the potential impact of space militarization.

Industrial Gas Turbines (IGT)

Industrial Gas Turbines (IGT) saw 4.2% growth between 2023 and 2024 but are projected to contract by 2.9% in 2025. Still, the long-term CAGR is estimated at 1.9% through 2026. While short- term trends are uneven, the long-term outlook is more bullish. Gas turbines are expected to play a critical role in powering data centers that support artificial intelligence—a market with vast energy demands. 

Near-term IGT market softness is likely temporary. Long-term prospects remain favorable, especially with the surge in AI-driven data center energy demand and expanded use of natural gas as a transitional fuel.

Automotive

Automotive saw solid demand in 2024, with the investment casting segment benefiting from both internal combustion and electric vehicle (EV) platforms. Data on U.S. passenger miles driven and light truck/auto assembly volumes from 2021 to 2027 confirm steady vehicle production. EVs continue to capture share, and cast components for drivetrain and thermal systems remain critical.

While vehicle assemblies in North America are stabilizing, technology shifts continue to reshape demand. Internal combustion engine (ICE) assemblies are declining slightly, while EVs are rising steadily.

Investment castings remain essential for EV drivetrain components, turbocharger parts, and thermal management systems.

General Industry

General Industry showed growth in several key areas:

Industrial Production: Annualized rates improved year over year from 2020 to 2024. Month-to-month industrial growth in 2023 vs. 2024 was also positive.

Firearms: U.S. firearm production across categories (pistols, revolvers, rifles, shotguns, and miscellaneous) remained robust from 2021–2024.

Oil & Gas: North American rig counts showed a strong CAGR from 2020–2024. While regional growth varied (Europe, APAC, Middle East), key metrics—including crude oil production, gas production, and casting demand—rose year over year. WTI spot prices and average pump prices tracked upward as well.

Orthopedic Implants: Industry trends were positive in 2024, with strong growth forecasts into 2025. Demand for cast orthopedic components— especially knees—is expected to remain elevated through 2027.

Medium & Heavy Truck Assemblies: Moderate growth continues, with positive CAGR figures in 2024 and further expansion forecast for 2025.


Market Forces & Policy Impacts

2024 was another year of policy whiplash, particularly around tariffs. Announcements, reversals, and reim- positions kept manufacturers on edge and led many to renegotiate shipping terms to account for changing costs. Meanwhile, government incentives including tariffs on imported vehicles- are prompting manufacturers to reassess production  locations  and  reinvest in North America. Environmental priorities are also shaping operations. Sustainability, resource optimization, and energy sourcing are now central to business strategy. These trends bode well for investment casting. As reshoring accelerates and U.S.-based production scales, demand for precision metal components is increasing across aerospace, automotive, energy, and industrial markets. 2025 will likely continue this expansion, albeit with caution around macro volatility.

Labor and Supply Chain

Labor remains a limiting factor. While hiring improved in 2024, most foundries still report extended lead times compared to pre-pandemic norms.

Trade & Tariffs

The status of US tarriffs remains fluid. These shifts created uncertainty across the supply chain, impacting sourcing strategies and inventory management. New duties on key components from Asia may introduce fresh challenges. As a result, U.S. investment casters are increasingly exploring domestic and nearshore suppliers to stabilize costs and lead times. Continued policy fluctuations are expected to influence purchasing behavior well into 2025.

Government Incentives

Policy-driven reshoring is accelerating. The CHIPS and Science Act, IRA, and infrastructure investments are spurring manufacturing growth.

  • $614 billion+ committed to U.S. reshoring and FDI projects since 2021

  • Tariffs on imported autos are pushing OEMs to localize more production

  • Sustainability mandates are increas- ing use of resource-efficient casting processes

Final Outlook

Across virtually every sector, investment casting demand in North America is expanding—driven by geopolitical forces, technology shifts, and policy support for domestic manufacturing. Aerospace remains the industry's linchpin, while general industry, IGT, and automotive provide diversification and growth opportunity.

 With solid fundamentals and increased domestic manufacturing investment, the 2025 outlook is bright—tempered only by persistent workforce constraints and global trade uncertainty.

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