Precision, Performance, and Partnership — Built from the Core
At Stahl Specialty Company, we understand that the success of an aluminum casting starts with a perfect core. For over 70 years, we’ve built a reputation as one of the largest and most advanced aluminum foundries in the United States. Specializing in permanent and semi-permanent mold aluminum casting, Stahl offers fully integrated, in-house core making services that meet the demands of high-complexity, high-volume production.
From intricate internal geometries to tight tolerances, our precision sand core manufacturing capabilities allow us to support complex castings across industries such as HVAC, automotive, marine, agriculture, heavy truck, robotics, and more. If your component demands engineering precision and consistent repeatability, Stahl is the aluminum foundry partner that delivers.
Core making is a critical process in aluminum casting that allows for the creation of internal cavities, passages, and complex geometries that cannot be formed using the mold alone. At Stahl, our in-house core making services include both hot cured (shell) and cold cured (SO₂) sand core manufacturing. These techniques enable the production of consistent, high-integrity cores tailored to your part’s geometry and performance requirements.
We support flexibility in sand grain sizes and resin compositions, giving our engineering team the tools to create optimized cores for both lightweight and heavy-duty components. Whether your part requires precision cooling channels, internal flow paths, or weight reduction features, our core making foundry services are engineered to meet the challenge.
At Stahl Specialty Company, core making isn’t just a support function — it’s a strategic advantage. Our in-house capabilities are designed to integrate seamlessly with our casting, machining, and assembly operations, streamlining the production process and reducing time to market.
We offer both hot cured shell cores and cold cured SO₂ cores, giving customers greater flexibility depending on thermal, dimensional, and cost considerations.
Our engineers can customize sand grain sizes and binder systems to meet specific tolerances, surface finishes, and strength requirements — ensuring every core is optimized for casting integrity and function.
Stahl operates the largest number of 48″ x 60″ rotary casting machines in the U.S., enabling us to handle both large-scale components and smaller, complex parts with precision. Our core shop is built for high volume — supporting casting volumes from 500 to over 2,000,000 units annually.
Stahl’s engineers work directly with your team to design and validate core configurations that maximize casting performance and manufacturability. This collaborative approach reduces downstream issues and enhances part consistency.
Every core and casting is subject to rigorous quality control processes. We integrate non-destructive testing such as X-ray, dye penetrant, leak testing, and CMM inspection to ensure the final part meets your exacting standards.
Many of the castings we produce at Stahl require intricate internal geometries that can only be achieved through expert core making. Our semi-permanent mold aluminum casting process benefits significantly from our in-house core production, allowing us to deliver:
By integrating the core making process within the foundry, we eliminate reliance on third-party core suppliers — giving us greater control over timing, quality, and technical optimization.
Our core making capabilities support demanding applications across a wide range of industries. Whether you’re producing heavy-duty components or lightweight, high-performance parts, Stahl delivers:
Choosing a core making partner isn’t just about capacity — it’s about capability. Stahl Specialty Company offers unmatched value to customers who require precision, volume, and vertical integration.
Vertically Integrated Production
From tooling and core making to casting, machining, heat treating, and assembly, everything happens under one roof. This eliminates handoffs, improves quality control, and shortens lead times.
Proven Engineering Support
Our team brings decades of experience in aluminum casting and core design. We help you identify part improvements, reduce scrap rates, and optimize your product for manufacturability.
ISO 9001:2015 Certified
We maintain strict quality standards across every stage of the process. Our commitment to excellence ensures repeatable performance, especially on mission-critical parts.
Advanced Equipment & Inspection
We utilize state-of-the-art equipment including CMMs, laser scanners, X-ray systems, and high-capacity grinding and machining centers to ensure your finished part exceeds expectations.
Scalable Volume & Complex Geometry Expertise
Stahl is uniquely positioned to handle both intricate castings and high-volume production. Our blend of technical skill and infrastructure is virtually unmatched in the industry.
If you need aluminum casting core making services that deliver both complexity and consistency — Stahl is ready. Our team of engineers and casting specialists is here to help bring your part from concept to casting with unmatched quality and precision.
Contact us today at sales@stahlspecialty.com or call (816) 597-3322 to speak with a core making expert.