From molten metal to the perfect cut: how TESUP casts and machines aluminium

A CNC cutter machining a steel mould beside a box of fresh cast aluminium covers with TESUP cast into the metal

October 21, 2026

Every TESUP wind turbine starts as aluminium. Here is how we turn it into parts that fit perfectly: we cast it, then we cut it.

Aluminium is light, strong and resists corrosion, which makes it ideal for a machine that lives outdoors in all weathers. But a part is only as good as the way it is made. That is why we keep the important steps in our own hands.

1. It starts with the mould

Before any metal is poured, the mould has to be right. Moulds are machined from solid blocks of steel, pass after pass, until every curve of the future part is there in the steel. A good mould means every part that comes out of it is the same.

Left: a CNC cutter machining the cavity of a steel mould. Right: a cast aluminium Magnum body resting on a mould plate — The mould is machined first. Then it shapes every part that follows.

2. Casting: aluminium takes shape

Molten aluminium fills the mould and takes its exact shape as it cools. These cast covers have just come out of the mould. You can still see the extra metal around the edges, and the TESUP name cast right into the part.

A box of raw cast aluminium covers, with the TESUP name cast into the top cover and casting edges still visible — Fresh from the mould, with our name cast into the metal.

On the lathe

Straight from the mould, every cover goes onto the lathe. The casting is chucked, spun up and faced so the bearing seat and the centre bore run perfectly true. The bright aluminium swarf piling up below is the part of the casting we remove to get from “cast” to “precise”.

Facing a motor cover on the lathe.

Finished aluminium motor covers with the TESUP name cast in, stacked after machining — Machined covers, ready for assembly.

3. Cutting it perfect

A casting is close to the final shape, but not close enough. So every part is machined: CNC machines take away the extra metal, face the surfaces flat and cut the seats and holes exactly where they need to be. That is what makes parts fit together cleanly, turn smoothly and stay sealed against the weather.

Three machined aluminium parts for the Magnum body on a workbench, each with a clean, bright machined finish and a small TESUP mark — Machined parts for the Magnum body: clean edges, bright surfaces, exact fit.

Laser-cut sheet

Not every part is cast. Flat parts are cut from aluminium sheet on our fibre laser, which follows the drawing to the line and leaves clean edges, ready for bending and assembly.

A fibre laser cutting bed with an aluminium sheet full of precisely cut parts

The result

Cast for strength, cut for precision. This is how the bodies and covers of our Atlas and Magnum turbines are made, and why they fit together the way they do.