At Castek Aluminum, we take pride in offering a comprehensive in-house solution for all your project needs. With our experienced staff, we oversee every aspect of your project, from concept development to the finished product and try-out. By keeping everything in-house, we maintain strict quality control measures and ensure timely delivery, giving you peace of mind throughout the entire process.

Structural Expandable Foam Molds

Castek offers several levels of open foam molds, from prototype to production aluminum molds. Castek’s metal handling processes allow us to provide excellent aluminum sand casting mold surfaces with integrated cooling and magnetic features to achieve embedded components, including Velcro and fastener.

Each expandable foam mold Castek manufactures is made with complete attention to detail during every facet of the project to serve the final product. From memory foam molds to foam seat molds.

Single & Twin Sheet Thermoform Tooling

Castek has manufactured temperature-controlled “precision cast” single and twin sheet vacuum form tools for almost three decades. We design our turn-key molds to produce the highest quality plastic parts in the industry. From part design to finished tool review with our customers, we ensure that all specifications have been met with an increased emphasis on details. There is typically no size limitation to our cast molds, and they are often 100% machined to maintain both dimensional and cosmetic quality.

Pressure Forming Tooling

Pressure-forming molds are in a class of their own. These temperature-controlled tools are generally machined 100%. They have an injection-molded appearance at a much lower price than its counterpart. In their specific design, these molds are geometrically intricate. They require both vacuum and pressure to produce the higher level of detail needed.

Compression Tooling

Since 1993, Castek has produced metal-matched compression tools for making carpet, foam, acoustic, RIM, and injection molded parts. These molds are cast oversized and machined 100%. They can be temperature-controlled with secondary/moving action to form severe undercuts with in-mold trimming capabilities. Moreover, Castek also provides 3rd party CMM work for mold verification against initial CAD data.

Inspection & Prototyping

The Romer Arm is a 3-meter reach machine capable of scanning 3-dimensional surfaces and does a comparative analysis to the CAD / CAM data provided.

  • Fully functional gantry press with 10-ton force with a 90” daylight and 36” stroke.
  • The heating system is soap dish infrared with a 105 x 72” work envelope. Zoned.
  • Vacuum pump set up to heat and form using plug assist on press
  • Thermolators to temp control mold halves for consistent process


  • Romer Laser CMM – 3-meter reach – calibrated and overhauled annually – ISO 17025 standards
  • Manual CMM arm – for manual layout – 60 x 84 x 216 work envelope
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