An optical fiber with both temperature and strain fiber Bragg grating sensors were embedded into an aluminum cast structure during the casting process. Temperature and strain calibrations were carried out respectively for the metal-embedded sensors. Temperature and external strain decoupling was further demonstrated in a temperature range from 25 to 80 °C and an external strain range from 0 to ∼110 µɛ. With the interpolated temperature measured by two temperature sensors at different positions, the external strain could be decoupled from temperature and thermal strain at the strain sensor. The temperature and external strain values obtained from our embedded optical fiber sensors agreed well with reference values, revealing the good performance of the metal-embedded optical fiber sensors. The difference between the measured values and the reference values are within ±5 µɛ for external strain and ±1 °C for temperature. With only a single fiber, the in-situ temperature and external strain information in the aluminum structure can be monitored in real time, representing an important step towards fiber-optic smart casts. Our investigation demonstrates that embedded optical fiber sensors can be a promising method for structural health monitoring of metallic structures.