Precision Sand Casting For EV Powertrain Components & Structural Body In White Parts

> Rapid Prototype Castings

We have a purpose-built prototype facility that allows us to rapidly manufacture complex, high-precision EV cast components to ensure proof of concept, integrity and validation before beginning large-scale production.

Our team of experienced engineers can achieve this by utilising our ‘Magmasoft® 32 Core’ virtual simulation software, accredited materials lab, 3D sand printing centre, robotically controlled foundry, cast validation lab (X-Ray/CT Scanning/GOM/Creaform) and dimensional validation lab (CMM).

This advanced approach to rapid prototyping allows us to produce EV cast components of the highest quality in just a few weeks, helping our customers significantly reduce the time it takes to develop electric vehicles.

> Lightweight Engineering

As leaders in our industry, we are helping to power the electric vehicle market by pioneering the development and manufacture of strong, lightweight, highly durable aluminium body in white structural parts.

We are continuing to push the boundaries by producing large body in white structural parts up to 3m² with a consistent minimum wall thicknesses of 2.5mm, a linear cast tolerance DCTG7 and a superfine surface finish of 4RA.

Through careful material research and innovation, we have developed lightweight body in white structural parts by using refined high silicon aluminium alloy series and low-volume sand cast production to effectively replicate the mechanical and geometric properties achieved with high-pressure die castings.

> Low/Medium Volume Series Sand Casting Foundry

At Finecast, we can support both initial production phase builds through to scheduled production volumes up to 5000 units, providing flexible solutions to our clients.

We understand the importance of high-precision, high-integrity and quality finished castings, especially when it comes to EV’s, and can produce a wide range of EV cast components including, electric drive units, battery enclosures and large structural body in white parts in-house thanks to our low/medium volume series foundry.

As innovations in this area thrive, we continue to commit investment and resources into securing the most advanced robotic foundry equipment. From automated mixing to high-speed mould filling and closing stations, we can save our customers time and money using repeatable processing suitable for components of up to 2m².

We are now able to reclaim up to 95% of the sand we use with our new state-of-the-art thermal sand reclamation system. This allows us to make our sand casting process more efficient and significantly lower our carbon footprint.

We can also optimise the sand quality during the thermal reclamation process, which results in exceptionally high-quality castings with superior surface finishes.

CNC Machining For EV Powertrain & Structural Body In White Castings

> Fine-Machine, Close Tolerance Complex Components

Our state-of-the-art machining division is equipped with the latest high-spec Mazak CNC machining centres and driven turning machine tools enabling us to offer a fully integrated service.

At Finecast, we have not only invested in the highest quality machine tooling technology, we also have a talented, experienced team of engineers specialising in CNC machining complex geometry and close tolerance components in a variety of material grades.

This enables us to guarantee repeatable, high-quality finished machined EV cast components.