Cast Aluminum Solutions is a thermal solutions supplier specializing in the design and manufacture of standard and custom aluminum cast heated parts. CAS's reputation for quality and rapid product development is enabled by precision manufacturing equipment and processes, cleanroom assembly and a hands-on design approach with its customers which minimizes the product development cycle and results in the highest quality products.CAS's manufacturing facility is fully dedicated to heated parts design and manufacturing and boasts a modern and innovative aluminum foundry for the production of porosity-free castings, state-of-the-art CNC machines and high-tech research labs. The company is a recognized leader in generating creative new ideas and evaluating, designing and prototyping to get products to market faster. It specializes in sensing and control systems, thermal-mechanical subsystems and computational engineering. CAS has been ISO: 9001 certified since 1994.

• Engineering Expertise – Creating products matching specific thermal and technical requirements
• Speed to Market – New Product Development Process enables faster delivery of custom products
• Operational Excellence - State of the art manufacturing facility embracing Lean principles

Creating Solutions from Concept to Reality

We specialize in the design and manufacture of highly engineered aluminum products that require high end casting, precision machining, assembly, and superior testing capabilities. While we specialize in thermal solutions we also use our core competencies for non-thermal applications. Our thermal products are comprised of heating elements, tubes or other components which are cast into an aluminum form (“cast-in products”). We create engineered parts which produce heating, cooling, or both, for specific applications. Our solutions utilize cast and non-cast technologies to make parts out of aluminum and a variety of other materials. Our non-thermal products are made with the same engineering and manufacturing expertise. Our 54,000 square foot facility in Batavia, Illinois houses a state of the art foundry, CNC mills and lathes, plus a variety of testing, assembly and inspection capabilities.

Engineering Expertise

The CAS Engineering team possesses extensive technical knowledge with decades of experience in design and manufacturing. The ability to design “heated parts” with excellent temperature uniformity is one of our specialties. Our engineering capabilities include Computer Aided Design (CAD), 3D modeling and Finite Element Analysis (FEA) services.Our engineers are also intimately familiar with the applications and markets where our products are used, including applicable industry standards and regulations. We have a long history of working closely with our customers engineering teams to develop the most effective product at the lowest cost.

Speed to Market with Quick Turn Prototypes

Moving a product from concept to reality is vital. The CAS New Product Development (NPD) process enables our customers to achieve their goal of delivering new products to market with speed. Our cross-functional team of engineers and technicians adhere to robust and proven processes.We have many options at our disposal to quickly produce castings for prototypes. Concepts and ideas are routinely validated by trial runs and lab testing, and all prototypes are thoroughly inspected for conformity to specifications. As a result, our customers receive new products which meet or exceed expectations on time. Our NPD process includes meticulous documentation which facilitates a seamless transition to production.

Operational Excellence

CAS operates a state-of-the-art manufacturing facility. The cast-in process begins with heater elements or tubes, which are precisely formed by our technicians using proprietary fixtures and tools assuring part-to-part repeatability. Our engineers and casting experts design mold tooling to control the casting process for optimal metallurgy.Our aluminum foundry features proprietary low-pressure cast technology. We also use the traditional gravity pour method for parts which are better suited to this process. Parts are machined to the tightest tolerances using computer numerical controlled (CNC) mills and lathes, with critical dimensions checked by coordinate measurement machine (CMM) to the hundred millionths of an inch. Our assembly capability includes electrical test and assembly, welding and brazing, cleaning and packaging. We maintain a class 10,000 positive pressure clean room for specialty applications.

Products and Markets

The Cast Aluminum Solutions product line offers a variety of solution approaches to the marketplace. Our engineered products give customers maximum flexibility to flawlessly integrate our parts into their equipment or systems. The flagship of our line is the cast-in heater, typically an aluminum part. We also make non-cast products such as the Interference Fit Construction (IFC) using our proprietary manufacturing process to install heater elements into wrought metal alloys. An off-the-shelf solution for liquid and gas heating is provided by our CAST-X family of circulation heaters. Standard aluminum platens offer a ready-made product for 200mm and 300mm silicon wafer processing. Cast Aluminum Solutions is a leading component supplier to the food service, semiconductor process, and medical equipment markets. We also service other markets including packaging, adhesive, plastics extrusion, factory infrastructure equipment, and aerospace systems.