# How Much Does Custom Aluminum Casting Cost in China? 2026 Price Guide
If you're sourcing custom aluminum casting parts—whether for automotive, aerospace, industrial machinery, or consumer products�?*China remains the world's most cost-effective manufacturing hub in 2026. But understanding the true total cost** requires looking beyond the per-piece price quote.
As an IATF 16949 certified aluminum casting manufacturer based in Ningbo, Zhejiang Province, Bohua Mechanical Parts has produced over 3,000 tons of aluminum castings annually since 2005, serving global OEMs and Tier-1 suppliers. In this comprehensive guide, we'll break down:
�?Tooling costs (molds/dies)
�?Unit casting prices (by alloy, weight, complexity, volume)
�?Secondary operations (machining, heat treatment, surface finishing)
�?Logistics and duties
�?Hidden costs most buyers overlook
By the end, you'll know how to budget accurately and negotiate confidently with Chinese aluminum foundries.
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Quick Cost Overview: What to Expect in 2026
Here's a ballpark estimate for a typical automotive gravity casting project (A356 aluminum, 2.5 kg part, moderate complexity):
| **Cost Component** | **Estimate (USD)** | **% of Total (1,000 pcs)** |
|---|---|---|
| **Tooling (one-time)** | $12,000�?18,000 | 20�?0% (first batch only) |
| **Unit casting price** | $22�?32/pc | 40�?0% |
| **Machining/finishing** | $8�?15/pc | 15�?0% |
| **Quality inspection** | $1�?3/pc | 2�?% |
| **Packaging** | $1�?2/pc | 2�?% |
| **Shipping (sea freight)** | $2�?5/pc | 4�?% |
| **Import duty (EU/US)** | $1.50�?4/pc | 3�?% |
| **Total (1,000 pcs, incl. tooling)** | **$47,500�?79,000** | 100% |
| **Unit cost (1,000 pcs)** | **$47.50�?79/pc** | �? |
| **Unit cost (5,000 pcs)** | **$37�?58/pc** | �?(tooling amortized) |
*Note: Prices vary significantly by part complexity, alloy, tolerances, and supplier. This is a representative mid-range example.*
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1. Tooling Costs: The Upfront Investment
Tooling (mold or die fabrication) is a one-time investment that's amortized across your production volume. The type of casting process determines tooling complexity and cost.
Gravity Die Casting (Permanent Mold)
Typical tooling cost: $8,000�?30,000
Factors influencing cost:
- •Part size: Larger molds require more steel and machining time
- •Complexity: Multiple cores, slides, or inserts add cost
- •Number of cavities: Single-cavity vs. multi-cavity (2-cavity molds cost ~1.6× single)
- •Material: H13 tool steel (standard) vs. specialized coatings
Example pricing (Ningbo supplier, 2026):
| Part Description | Mold Cost | Mold Life (Cycles) | Cost per Part (Tooling Only) @ 5,000 pcs |
|---|---|---|---|
| Simple bracket (1 kg, single cavity) | $8,500 | 80,000 | $1.70 |
| Heat exchanger housing (3 kg, 2 cores) | $15,000 | 60,000 | $3.00 |
| Complex transmission case (6 kg, 4 slides) | $28,000 | 50,000 | $5.60 |
Mold lifespan: 50,000�?00,000+ cycles with proper maintenance.
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Pressure Die Casting (HPDC)
Typical tooling cost: $15,000�?80,000
Why it's more expensive:
- •Must withstand high injection pressure (700�?,500 bar)
- •Requires H13 steel with surface hardening (HRC 48�?2)
- •More complex cooling channels for rapid cycle times
Example pricing:
| Part Description | Die Cost | Die Life (Cycles) | Cost per Part (Tooling Only) @ 10,000 pcs |
|---|---|---|---|
| Small electronic housing (0.3 kg, ADC12) | $18,000 | 150,000 | $1.80 |
| Automotive gearbox cover (2 kg, ADC12) | $35,000 | 120,000 | $3.50 |
| Large motor housing (8 kg, 4 slides) | $75,000 | 100,000 | $7.50 |
Die lifespan: 80,000�?00,000 cycles depending on alloy and maintenance.
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Sand Casting
Typical pattern cost: $1,500�?5,000
Why it's cheaper:
- •Patterns are simpler (wood, resin, or 3D-printed)
- •No high-pressure requirements
- •Can produce large, complex shapes without expensive tooling
Trade-off: Higher per-unit cost (see section 2).
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Tooling Payment Terms (China)
Standard terms:
- •50% deposit upon order confirmation
- •50% balance upon first article inspection approval
Ownership: Tooling typically remains with the supplier, but you can negotiate:
- •Tooling buyout clause (add 20�?0% to tool cost for full ownership)
- •Exclusive use rights (prevents supplier from using your mold for other customers)
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2. Unit Casting Price: Per-Piece Cost Breakdown
The raw casting cost (before machining) depends on:
- •Alloy type (aluminum grade)
- •Part weight (material cost)
- •Casting complexity (labor, scrap rate)
- •Production volume (economies of scale)
- •Quality requirements (automotive IATF 16949 vs. general industrial)
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Aluminum Alloy Pricing (Ningbo, 2026)
| Alloy | Common Name | Typical Use | Raw Material Cost (CNY/kg) | Raw Material Cost (USD/kg) |
|---|---|---|---|---|
| **A356 (AlSi7Mg0.3)** | ZL114 (China) | Gravity casting, structural parts | ¥22�?6 | $3.10�?3.65 |
| **ADC12 (AlSi11Cu3)** | �? | High-pressure die casting | ¥19�?3 | $2.65�?3.20 |
| **6061-T6** | �? | Machined parts (not typically cast) | ¥28�?2 | $3.90�?4.50 |
| **A380** | �? | Die casting, general use | ¥20�?4 | $2.80�?3.35 |
*Exchange rate: 1 USD = 7.15 CNY (2026 average)*
Why A356/ZL114 is more expensive:
Higher magnesium content improves mechanical properties but increases material cost by 15�?0% vs. ADC12.
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Gravity Die Casting Unit Pricing (China)
Formula:
*Unit Casting Cost = (Material Cost × Weight × 1.1) + Labor + Overhead + Scrap Allowance*
- •Material multiplier (1.1): Accounts for runners, gates, and scrap
- •Labor cost: $0.80�?2.50/pc (depending on complexity)
- •Overhead: 15�?5% (energy, facility, QC)
- •Scrap allowance: 3�?% (built into pricing)
Example: A356 Gravity Casting (2.5 kg part)
| Volume | Material Cost | Labor | Overhead | Total Unit Price |
|---|---|---|---|---|
| 100 pcs | $8.50 | $2.20 | $2.70 | **$13.40/pc** |
| 500 pcs | $8.50 | $1.80 | $2.10 | **$12.40/pc** |
| 1,000 pcs | $8.50 | $1.50 | $1.80 | **$11.80/pc** |
| 5,000 pcs | $8.50 | $1.20 | $1.50 | **$11.20/pc** |
Real-world pricing (Ningbo IATF 16949 supplier, 2026):
- •Simple parts (1�? kg, no cores): $8�?14/kg
- •Moderate complexity (2�? kg, 1�? cores): $12�?18/kg
- •Complex parts (4�? kg, 3+ cores, slides): $16�?25/kg
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High-Pressure Die Casting (HPDC) Unit Pricing
ADC12 example (1.2 kg part, automotive electronics housing):
| Volume | Material Cost | Labor | Overhead | Total Unit Price |
|---|---|---|---|---|
| 1,000 pcs | $3.80 | $1.50 | $1.20 | **$6.50/pc** |
| 5,000 pcs | $3.80 | $0.90 | $0.85 | **$5.55/pc** |
| 10,000 pcs | $3.80 | $0.70 | $0.65 | **$5.15/pc** |
HPDC is cheaper per piece at high volumes due to:
- •Faster cycle times (60�?20 seconds vs. 5�?5 minutes for gravity)
- •Higher automation (less labor)
- •Better material yield (thinner walls possible)
Trade-off: Higher tooling cost and minimum order quantities (MOQ typically 1,000�?,000 pcs).
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Sand Casting Unit Pricing
A356 sand casting (5 kg part, industrial pump housing):
| Volume | Material Cost | Labor (Manual Molding) | Overhead | Total Unit Price |
|---|---|---|---|---|
| 50 pcs | $17.50 | $12.00 | $4.50 | **$34.00/pc** |
| 200 pcs | $17.50 | $10.00 | $3.80 | **$31.30/pc** |
| 500 pcs | $17.50 | $8.50 | $3.20 | **$29.20/pc** |
Why sand casting unit costs stay high:
- •Each mold is single-use (high labor per part)
- •Lower dimensional accuracy �?more machining needed
- •Higher porosity �?lower yield after inspection
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3. Secondary Operations: Often 30�?0% of Total Cost
Most aluminum castings require post-casting operations before they're ready for assembly:
Machining
Purpose: Achieve tight tolerances, threads, sealing surfaces
Cost drivers:
- •Machining time: $0.60�?1.50/minute (CNC machining in China)
- •Complexity: Simple facing vs. multi-axis milling
- •Tolerance: ±0.05 mm costs 2�?× more than ±0.2 mm
Example: Heat Exchanger Housing (A356, 2.8 kg)
- •As-cast price: $14/pc
- •Machining required: Face sealing surfaces, drill 8 holes, tap 4 threads
- •Machining time: 18 minutes
- •Machining cost: $18�?27/pc
- •Total: $32�?41/pc
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Heat Treatment (T6)
Purpose: Improve mechanical properties (strength, hardness)
Process: Solution treatment (520°C, 8 hrs) + quench + aging (155°C, 6 hrs)
Cost: $1.50�?3.50/kg
Example: A356-T6 (2.5 kg part): $3.75�?8.75/pc
When to skip: Non-structural parts, cost-sensitive applications.
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Surface Finishing
| Finish Type | Purpose | Cost (CNY/m²) | Cost (USD/m²) | Typical Part Cost (0.2 m² surface) |
|---|---|---|---|---|
| **Shot blasting** | Remove scale, improve surface | ¥15�?5 | $2.10�?3.50 | $0.42�?0.70/pc |
| **Powder coating** | Corrosion protection, color | ¥35�?0 | $4.90�?7.00 | $0.98�?1.40/pc |
| **Anodizing (Type II)** | Corrosion, wear resistance | ¥50�?0 | $7.00�?11.20 | $1.40�?2.24/pc |
| **Electropolishing** | Ultra-smooth finish | ¥120�?80 | $16.80�?25.20 | $3.36�?5.04/pc |
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Leak Testing (Automotive/Aerospace)
Methods: Helium leak detection, pressure decay
Cost: $2�?8/pc (depending on test severity)
When required: Fluid-carrying parts (housings, manifolds, heat exchangers).
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4. Quality Inspection & Certification Costs
Standard QC (Included in Base Price)
- •Dimensional inspection (CMM sampling, 1�?% of batch)
- •Visual inspection (100%)
- •Material traceability (heat lot numbers)
Advanced QC (Adds Cost)
- •PPAP documentation (Production Part Approval Process): $1,500�?5,000 one-time
- •FAI (First Article Inspection): $800�?2,500
- •X-ray inspection (porosity): $3�?10/pc
- •Metallurgical analysis: $150�?400 per batch
- •Third-party inspection (SGS, TÜV): $500�?1,500/visit + $2�?5/pc
IATF 16949 certified suppliers include most QC in their base price but charge extra for customer-specific requirements.
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5. Packaging & Logistics Costs
Packaging
- •Standard export packing (plywood crate, foam, anti-rust paper): $1�?2/pc
- •Custom packaging (individual boxes, branding): $2�?5/pc
Shipping from Ningbo/Shanghai to Major Markets (2026)
| Destination | Sea Freight (20' container) | Transit Time | Cost per Part (500 kg shipment) |
|---|---|---|---|
| **Los Angeles (USA)** | $1,800�?2,500 | 18�?2 days | $3.60�?5.00/pc |
| **Hamburg (Germany)** | $2,200�?3,000 | 28�?2 days | $4.40�?6.00/pc |
| **Rotterdam (Netherlands)** | $2,100�?2,800 | 26�?0 days | $4.20�?5.60/pc |
| **Dubai (UAE)** | $1,200�?1,800 | 16�?0 days | $2.40�?3.60/pc |
Air freight (urgent orders):
- •$4.50�?7.00/kg (5�? days)
- •Example: 2.5 kg part = $11.25�?17.50/pc shipping
Incoterms matter:
- •EXW (Ex Works): Buyer arranges all shipping
- •FOB (Free On Board): Supplier handles to port, buyer pays sea freight
- •DDP (Delivered Duty Paid): Supplier handles everything to your door (add 8�?5% to FOB price)
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6. Import Duties & Taxes (2026)
United States
- •Aluminum castings (HS 7616.99): 2.5�?.0% duty
- •Section 301 tariffs (China-specific): 7.5�?5% (varies by product category; some aluminum parts exempted)
- •Total effective duty: 10�?0%
Example: $50/pc casting �?$5�?15/pc import duty.
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European Union
- •Aluminum castings (CN 7616 99 10): 6.0% duty
- •VAT: 19�?7% (varies by country; paid by buyer, not supplier)
Example: $50/pc casting �?$3/pc duty + $10�?13.50/pc VAT (refundable for VAT-registered businesses).
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Trade Agreements & Exemptions
- •ASEAN countries: 0�?% duty (via ACFTA)
- •South Korea, Japan: 0�?% (via RCEP)
- •UK: 6% (post-Brexit, similar to EU)
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7. Hidden Costs Most Buyers Overlook
Engineering & Design Support
- •DFM (Design for Manufacturability) review: Often free for serious buyers
- •Mold flow analysis: $500�?1,500 (recommended for complex parts)
- •Prototyping (3D-printed patterns): $300�?1,200
Mold Modifications
- •Minor adjustments (dimensions): $500�?2,000
- •Major rework (add slides, change parting line): $3,000�?10,000
Pro tip: Build a +5% engineering change allowance into your first-year budget.
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Payment Terms Impact Cash Flow
Standard terms:
- •30% deposit with order
- •70% balance before shipment
Negotiable for established buyers:
- •50/50 split (50% deposit, 50% at shipment)
- •Net 30�?0 days (after proving payment history)
Letter of Credit (L/C): Adds $500�?1,500 in bank fees but protects both parties.
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Currency Fluctuation Risk
CNY/USD exchange rate has ranged from 6.30�?.35 over the past 3 years.
Example impact:
- •Quote received at 7.00 CNY/USD: ¥140,000 order = $20,000
- •Payment made at 7.30 CNY/USD: Same order now costs $19,178 (saving $822)
Mitigation: Lock in exchange rate with forward contracts or request USD pricing for large orders.
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Quality Failures & Rework
Industry average reject rate:
- •IATF 16949 certified foundry: 0.5�?%
- •Non-certified supplier: 3�?0%
Cost of failure:
- •Scrap parts: Lost material + labor
- •Rework: $5�?20/pc
- •Delayed shipment: Air freight premium ($10�?30/pc)
Lesson: Choosing a certified supplier with proven quality systems saves more than the 5�?0% premium they charge.
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8. Total Cost Ownership (TCO) Example
Project: Automotive transmission oil pan cover
Material: A356-T6 aluminum, gravity die casting
Weight: 3.2 kg
Volume: 2,000 pcs/year (automotive production lifecycle: 5 years = 10,000 total)
Cost Breakdown (Ningbo IATF 16949 Supplier)
| Cost Element | Year 1 (2,000 pcs) | Year 2�? (8,000 pcs total) | Total (10,000 pcs) |
|---|---|---|---|
| **Tooling (one-time)** | $18,000 | �? | $18,000 |
| **Raw casting** | $38,400 ($19.20/pc) | $147,200 ($18.40/pc) | $185,600 |
| **Machining** | $26,000 ($13/pc) | $96,000 ($12/pc) | $122,000 |
| **T6 heat treatment** | $9,600 ($4.80/pc) | $36,800 ($4.60/pc) | $46,400 |
| **Powder coating** | $3,400 ($1.70/pc) | $13,120 ($1.64/pc) | $16,520 |
| **QC & inspection** | $3,000 ($1.50/pc) | $11,200 ($1.40/pc) | $14,200 |
| **Packaging** | $2,800 ($1.40/pc) | $10,880 ($1.36/pc) | $13,680 |
| **Sea freight (FOB Ningbo)** | $7,000 ($3.50/pc) | $26,400 ($3.30/pc) | $33,400 |
| **US import duty (15%)** | $1,200 | $4,560 | $5,760 |
| **Total** | **$109,400** | **$346,160** | **$455,560** |
| **Unit cost (amortized)** | **$54.70/pc** | **$43.27/pc avg** | **$45.56/pc avg** |
Cost Reduction Over Lifecycle
- •Year 1: $54.70/pc (includes tooling amortization)
- •Year 2�?: $43.27/pc average (tooling paid off)
- •Overall TCO: $45.56/pc
Comparison to domestic production (USA):
- •Estimated domestic cost: $78�?95/pc
- •Savings by sourcing from China: $32.44�?49.44/pc (42�?2%)
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9. Cost Optimization Strategies
Reduce Tooling Costs
�?Start with single-cavity molds (upgrade to multi-cavity for volume)
�?Simplify part design: Eliminate undercuts, reduce cores
�?Use standard mold bases: Don't custom-engineer unless necessary
�?Negotiate multi-project packages: Bundle 2�? projects for 10�?5% discount
Reduce Unit Costs
�?Optimize part weight: Every 100g saved = $0.30�?0.50/pc
�?Minimize machining: Design for as-cast features where possible
�?Relax tolerances: ±0.3 mm vs. ±0.1 mm can save 15�?5% machining cost
�?Batch heat treatment: T6 costs drop 20�?0% for full-furnace loads
Reduce Logistics Costs
�?Consolidate shipments: Full container loads (FCL) cheaper than LCL
�?Plan ahead: Sea freight vs. rush air freight saves $10�?30/pc
�?Use FOB Incoterms: Negotiate your own freight rates
Reduce Risk
�?Request PPAP upfront: Catches issues before mass production
�?Order T1 samples: 5�?0 pcs for validation ($500�?1,500 investment)
�?Build in quality holdback: Pay final 10% after inspection pass
�?Use escrow or L/C: Protects against non-delivery
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10. Why Sourcing from Ningbo, China Makes Economic Sense
Cost Advantage Breakdown (vs. Western Europe/North America)
| Cost Factor | China (Ningbo) | Western Europe | North America | China Advantage |
|---|---|---|---|---|
| **Labor (machining)** | $0.80�?1.50/min | $2.50�?4.00/min | $2.00�?3.50/min | 50�?0% lower |
| **Aluminum alloy (A356)** | $3.10�?3.65/kg | $4.20�?5.00/kg | $3.80�?4.50/kg | 15�?0% lower |
| **Tooling (gravity mold)** | $12,000�?20,000 | $25,000�?45,000 | $20,000�?35,000 | 40�?5% lower |
| **Energy (industrial)** | $0.08�?0.11/kWh | $0.18�?0.30/kWh | $0.10�?0.16/kWh | 30�?0% lower |
Net result: 30�?0% total cost savings, even after factoring in shipping and duties.
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Ningbo-Specific Advantages
�?Mature casting cluster: 500+ foundries, strong supply chain
�?Port proximity: 2 hours to Shanghai port (China's largest)
�?IATF 16949 certification density: 50+ automotive-certified foundries
�?English-speaking technical teams: Common in export-focused companies
�?Scalability: Can ramp from 1,000 to 50,000 pcs without relocating
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11. Frequently Asked Questions
Q: What's the minimum order quantity (MOQ) for custom aluminum casting?
A: Gravity casting: 100�?00 pcs; HPDC: 1,000�?,000 pcs; Sand casting: 10�?00 pcs. IATF-certified suppliers often accept lower MOQs for qualification projects.
Q: How long does it take from order to delivery?
A: First order: 10�?4 weeks (tooling + samples + production). Repeat orders: 4�? weeks.
Q: Can I visit the factory before placing an order?
A: Yes—most Ningbo foundries welcome audits. Some offer virtual factory tours via video call.
Q: What if the parts don't meet specifications?
A: Reputable suppliers offer rework or refund for non-conforming parts. Always request a quality guarantee clause in contracts.
Q: How do I verify IATF 16949 certification?
A: Ask for the certificate number and verify it on the IATF database.
Q: Can you ship directly to my contract manufacturer (CM)?
A: Yes—most suppliers offer drop-shipping to CMs or assembly partners.
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12. Getting an Accurate Quote: What to Provide
To receive a detailed, accurate quote from a Chinese aluminum foundry, send:
Technical Files
�?3D CAD model (STEP, IGES, or SolidWorks format)
�?2D engineering drawings (with tolerances, surface finishes)
�?Material specification (A356, ADC12, or equivalent)
Production Requirements
�?Annual volume forecast (helps determine tooling strategy)
�?Quality standards (IATF 16949, ISO 9001, customer-specific requirements)
�?Surface finish needs (as-cast, powder coating, anodizing)
�?Packaging requirements (standard export or custom)
Delivery & Commercial Terms
�?Target delivery date
�?Preferred Incoterms (EXW, FOB, DDP)
�?Payment terms (standard is 30/70; negotiate if needed)
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Ready to Get Competitive Quotes?
Ningbo Bohua Mechanical Parts Co., Ltd. has been a trusted partner for automotive OEMs and Tier-1 suppliers worldwide since 2005.
Our Capabilities:
�?IATF 16949:2016 + ISO 9001:2015 certified
�?3,000+ tons annual capacity (A356, ZL114, ADC12)
�?Gravity die casting (1�?5 kg parts)
�?High-pressure die casting (0.2�? kg parts)
�?In-house T6 heat treatment and full CNC machining
�?PPAP, FAI, APQP documentation for automotive projects
�?English/German/French technical support
Get Your Custom Quote:
📧 Email: sales@bohua-casting.com
🌐 #0f1e3d]">Website: [www.bohua-casting.com
📞 WhatsApp: +86-574-xxxx-xxxx *(request via email)*
Send us your CAD files and requirements—we'll provide:
- •Detailed cost breakdown (tooling, unit price, secondary ops)
- •DFM recommendations to optimize cost
- •Lead time estimates
- •Material certificates and capability documents
First-time buyers: Ask about our prototype program�?�?0 T1 sample parts at cost, with tooling credit applied to your production order.
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About the Author
This pricing guide was prepared by the engineering and sales team at Ningbo Bohua Mechanical Parts Co., Ltd., an IATF 16949 certified aluminum casting foundry serving automotive and industrial clients globally. Our mission is transparent pricing, reliable quality, and long-term partnerships.
Visit our website for additional resources, case studies, and technical whitepapers on aluminum casting processes.
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Last Updated: March 2026
Disclaimer: Prices and terms reflect 2026 market conditions and are subject to change based on material costs, exchange rates, and individual project specifications. Always request a formal quote for your specific requirements.
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#0f1e3d]">🌐 Request Quote: [Get Your Free Quote
*IATF 16949 certified · 3,000+ tons annual capacity · Serving global OEMs since 2005*