Top Industrial Applications of Metal Parts in Automotive and Aerospace 2025?
As automotive and aerospace industries advance toward electric vehicles, unmanned aircraft, and supersonic travel, demand for high-precision, lightweight, and durable metal parts has surged. In 2025, these parts are essential for performance, safety, and innovation.
This guide covers:
- What metals are used in aerospace and automotive
- Key applications across both industries
- Why custom machining is essential
- How Prime supports critical production needs
I’ll share technical insights, real use cases, and actionable takeaways for engineers and procurement managers evaluating suppliers.
Table of Contents
- 1. What Metals Are Used in the Aerospace Industry?
- 2. What Metals Are Used in the Automobile Industry?
- 3. What Is Steel Used for in Aerospace?
- 4. What Are the Applications of Metal Parts Across Industries?
- 5. Benefits of Custom Metal Parts in Critical Sectors
- 6. Prime’s Capabilities & Solutions
- 7. Manufacturing Workflow at Prime
- 8. Quality & Certification Standards
- 9. Case Studies
- 10. Selection & Cost Optimization Guidance
- 11. FAQs
- 12. Conclusion
1. What Metals Are Used in the Aerospace Industry?
Aerospace thrives on materials that offer superior stiffness, high-temperature strength, and corrosion resistance under extreme conditions. Let’s examine:
1.1 Titanium (e.g., 6Al-4V)
- Properties: Excellent strength-to-weight (< 4.5 g/cm³), corrosion-resistant, biocompatible
- Uses: Engine blades, airframe elements, landing gear pivots
1.2 Aluminum Alloys (e.g., 2024, 6061, 7075)
- 2024: strong, good fatigue resistance;
- 6061: weldable, machinable;
- 7075: high strength, used in aircraft structure
1.3 Nickel-based Superalloys (e.g. Inconel 718)
- Maintain strength at >700 °C
- Used for turbine discs, combustion chambers, exhaust systems
1.4 Stainless & Specialty Steels (e.g. 17-4PH, 15-5PH)
- Provide fatigue strength and dimensional precision
- Used in fasteners, shafts, sequence disc assemblies
Why These Metals?
- They comply with standards: AS9100, ISO 9001, AMS…
- NASA and SAE outline material Grades: NASA materials and SAE Standards
2. What Metals Are Used in the Automobile Industry?
Automotive is fueling innovation through lightweighting, electrification, and increased crash performance. Materials play a key role:
2.1 High-Strength / Advanced High-Strength Steel (AHSS)
- Yields 450–1500 MPa;
- Critical for structural brackets, safety cell, chassis cross-members
2.2 Aluminum Alloys (6XXX & 7XXX series)
- Used in engine compartments, EV housings, body panels
- Offers lightness and cost efficiency
2.3 Magnesium Alloys
- About one third the density of aluminum
- Ideal for housings, structural brackets
2.4 Copper & Copper Alloys
- Key for EV motors, wiring harnesses, thermal management systems
Trends:
- EV platforms boost usage of thermal copper parts
- Body structure transitions to hybrid aluminum-steel construction
Sources overview: WorldAutoSteel & AutomotiveWorld
3. What Is Steel Used for in Aerospace?
Though lighter metals dominate primary structures, the aerospace industry relies on steel for strength and precision in key systems:
3.1 Landing Gear
- Steel 300M, 4340M
- High resistance to tensile stress, load cycles, impact
3.2 Actuator Shafts & Valve Pins
- Made from 17‑4PH, 15‑5PH stainless
- Excellent fatigue resistance
3.3 Fasteners, Brackets, Interfaces
- Stainless or alloy steel with surface, process certifications
- Critical in cabin doors, safety systems, control linkages
3.4 Steel Tolerates
- Temperature up to 600 °C;
- Surface hardness and finish to microns
Refer to material references at ASM Aerospace Spec Metals & AircraftMaterials
4. What Are the Applications of Metal Parts Across Industries?
Metal parts drive critical industries thanks to their mechanical, thermal, and electrical properties.
4.1 Aerospace
- Engine and structural components, actuators, landing gear, fasteners
4.2 Automotive
- Crash structures, housings, wheel hubs, suspension subframes
4.3 Medical
- Surgical tools, implants (Ti/SS), sterilizable housings
4.4 Energy
- Heat exchangers, wind turbine brackets, steam turbine rotors, battery modules
4.5 Electronics & Telecom
- EMI shielding, housing, connectors
4.6 Industrial & Infrastructure
- Valves, hydraulic components, custom fittings
These parts leverage CNC machining, casting, stamping, or welding, designed for volume, cost, or complexity requirements.
5. Benefits of Custom Metal Parts in Critical Sectors
Off-the-shelf parts can’t meet the tolerance and performance demands of aerospace and new-gen automotive systems.
Key Advantages:
-
Precision & Consistency
- Guaranteed to ±0.005 mm
-
Design Flexibility
- Optimized geometry, weight reduction, heat control
-
Material Traceability
- Full certification from steel mill to CNC part
-
Durability & Lifespan
- Optimized surface coatings, treatments
-
Assembly Simplification
- Fit-first, no rework
-
Service & Maintenance Ready
- Modular inserts ease maintenance
Prime’s clients saved \~45–55% scrap by switching to custom CNC parts over die-cast alternatives.
6. Prime’s Capabilities & Solutions
6.1 Infrastructure
- Ten dedicated CNC and EDM lines
- 200T+ Stamping presses
- Production capacity 10M+ parts/year
6.2 Material Expertise
- Aluminum, Steel, Titanium, Nickel, Copper alloys
- P20, H13, NAK80, 17‑4PH, 7075, 6Al‑4V, Inconel
6.3 Process Capabilities
- CNC 3/4/5-Axis Machining
- Wire / Sinker EDM
- Precision Grinding
- Die Casting & Investment Casting
- Stamping & Automated Welding
- Surface Treatment: Anodizing, Passivation, Cerakote
6.4 Quality Assurance
- ISO 9001 certified
- AS9100, IATF 16949 support
- CMM reports, FAI, PPAP, traceability
6.5 Delivery & Service
- 7‑15 day production lead times
- ISPM-15 export packaging
- After-sales: tool life tracking, inserts & wear maintenance
7. Manufacturing Workflow at Prime
-
Inquiry & Quotation
- Submit CAD, choose materials, propose quantities
-
Design for Manufacturability (DFM)
- Free DFM review, gate, cooling, wall thickness for molds
-
Material Procurement
- Full-traceable certification and lab testing
-
CAM & Simulation
- Moldflow, Moldex3D, NC programming
-
Tooling & Machining
- CNC → EDM → Grinding → Polishing
-
Assembly & Trial Runs
- T0/T1 shots, CMM feedback, optimization
-
Inspection & Documentation
- CMM, FAI reports, steel certificates, packaging
-
Shipping & Lifecycle Support
- ISPM crates, CE/CoC, spare parts, after-sales
8. Quality & Certification Standards
- ISO 9001: Global quality system
- AS9100: Aerospace-specific QA
- IATF 16949: Automotive QMS
- NADCAP: Specialty process accreditation
- ROHS / REACH / CE: Regulatory compliance
- MTR, PMI, FAI, PPAP, CMM Reports
Prime supports OEM documentation including electrostatic sensitive packaging (ESD) and CoC.
9. Case Studies
9.1 Automotive EV Battery Tray
- 7075 aluminum with threaded steel inserts
- ±0.004 mm planar accuracy in 32-seat CNC machining
9.2 Aerospace Engine Bracket
- Titanium 6Al4V
- 5-axis CNC, heat-treated, custom anodizing
9.3 High-Speed Valve Body
- Inconel 718
- Investment casting, 200 µm wall, polishing, NDT inspection
10. Selection & Cost Optimization Guidance
| Part Period | Material | Process | Supplier Tip |
|---|---|---|---|
| Prototype | Aluminum | Machining | Use soft tools for fast delivery |
| Short run | Stainless | CNC | No cast needed, accuracy prime |
| Long run | Titanium/Al-Ni | Casting + finish | Balance cost & complexity |
| Lightweight Needed | Mg alloy | CNC + plating | Safety and handling design important |
For budget planning, use Xometry Mold Cost Estimator
11. FAQs
- What tolerances are possible? ±0.005 mm trackable
- Do you offer first article inspection? Yes; FAI, PPAP included for key industries
- What delivery times? 7‑15 days; expedited options available
- Can you manage complex metal types? Yes; Titanium, Inconel, Mg alloys
- Is custom packaging included? Yes; ISPM-15 safe export crates
12. Conclusion
Custom metal parts define advanced manufacturing in 2025. From EV frames to jet engine components, precision parts ensure innovation, performance, and ROI.
Prime delivers:
- Certified precision machining
- Engineering collaboration and DFM support
- Fast lead times and complete documentation
📞 Email: [email protected]
🌐 Website: https://primecustomparts.com
Let’s build the future together—one precision part at a time.
