Super-Fast Manufacture of High-Performance Castings for the Motorsport Industry
World-Leading Motorsport Casting Specialists
Combining industry-leading foundry technology and extensive experience to innovate casting manufacture and deliver geometrically complex, lightweight castings for the motorsport industry worldwide.
Speak to an expert
Discuss your objectives with a casting development engineer today!
32 Core MAGMA Simulation
3D Mould Pack Design
Tool-less 3D Sand Printing
Prototype & Series Foundry
5-Axis CNC Matching
Metallurgy, NDT, CMM
The Complete Design & Manufacturing Hub for Creating Complex, Lightweight, High-Performance Motorsport Castings
Finecast designs, engineers and manufactures complex, lightweight, performance-enhancing sand castings for some of the world’s leading motorsport companies including McLaren, Porsche, Aston Martin, Xtrac and Ilmor.
For the past 21 years, we have been an industry leader and continue to pioneer innovations in sand casting production, pushing the boundaries and revolutionising how we manufacture motorsport castings, allowing for complete design freedom, greater accuracy and precision, guaranteed integrity and super fast turnaround times.
We produce high-precision sand castings for motorsport powertrains, transmissions (ICE, Hybrid, EV) and body structures, including engine blocks, cylinder heads, transmission housings, turbine housings, compressor housings, exhaust manifolds, ladder frames, body-in-white structural parts and any applications that require complex geometric cast shapes. We manufacture in wide range of materials including aluminium, copper and nickel alloy and specialist steel and iron grades.
Finecast offers a complete single-source solution for the manufacture of motorsport sand castings from our state-of-the-art facility, based in Littlehamption, West Sussex. Through decades of dedication and investment we have developed a unique technologically advanced manufacturing process, which includes Virtual Casting Simulation, 3D Mould Pack Design, 3D Sand Printing, Foundry Tooling, Material Testing, Rapid Prototyping, Low/medium Volume Series Foundry Manufacture, Non-Destructive Testing and Integrity Validation, 5-axis CNC Machining and Dimensional Validation.
Our advanced manufacturing facility, technical processes and engineering experience enables us to deliver each and every casting exactly to your specifications, meet tight deadlines and produce castings of the very highest quality standard.
Find out more about our facility, processes and latest motorsport casting projects and see why we are the perfect partner for your next project.
Chevrolet 2.2L V6 IndyCar Engine Castings For Ilmor
“On behalf of the company owners and the whole team here, I would personally like to thank you and your company for the contribution in helping us achieve these goals. You are an important partner to Ilmor and your continued support is highly valued by ourselves. With your support, we look to continued success on the track”
Precision Sand Casting for Motorsport Applications
> Rapid Prototype Castings
Our custom-built prototype facility offers repeatable rapid manufacture of superior quality, geometrically complex components to the Motorsport industry, providing tangible proof of concept, comprehensive integrity examination and validation before transitioning into series production.
We achieve this through the utilisation of industry-leading Virtual Simulation Software ‘Magmasoft®’, our accredited Materials Laboratory, 3D Sand Printing Centre, Low/medium Volume Series Foundry, Heat Treatment Facility, Cast Verification Lab (CT & RT Scanning/GOM/Creaform) and Dimensional Validation Lab (CMM), in combination with our vast expertise in motorsport engineering.
Our unique rapid prototyping manufacturing process ensures high-quality motorsport components can be cast within days of recieving customer data, significantly reducing product development time and giving our customers a significant edge in their respective markets.
> Lightweight Engineering
Finecast is helping to revolutionise the motorsport industry with the production of lightweight, thin-walled, high-strength aluminium structural parts.
Through extensive material research and innovation in lightweight body-in-white structural parts, we have developed a proprietary high silicon aluminium alloy series designed to replicate the geometry and mechanical properties of high-pressure die castings.
This enables us to manufacture aluminium body-in-white structural parts with a consistent minimum wall thickness of 2.5mm and up to 3 meters in length.
> Low/Medium Volume Series Sand Casting Foundry
Our technologically advanced foundry offers the flexibility to support low-to-medium volume production of high precision motorsport components. We take great pride in the quality of our castings, with a focus on both mechanical integrity and surface finish.
Our state-of-the-art robotic foundry equipment includes automated mixers, high-speed mould filling and closing stations for components up to 2 msq. In addition, our foundry includes an advanced heat treatment facility and a thermal sand reclamation system that allows us to reclaim up to 95% of the sand we use.
We strive for exceptional quality, while also aiming to reduce our carbon footprint through efficient manufacturing practices.
Testing & Validation for Motorsport Castings
At our in-house laboratory, we leverage our state-of-the-art laser spectrographic equipment to ensure complete traceability of process parameters and validate the chemical composition and mechanical properties of all types of sand media and casting material. Our team of highly skilled and MA-qualified metallurgists conduct rigorous spectrographic analysis on melt samples throughout production to guarantee that the chemical composition meets your exact engineering specification.
Thanks to our comprehensive spectrographic analysis process, we can achieve repeatable results and consistently produce defect-free, high-integrity motorsport castings every time. We have extensive experience in this field which enables us to create alloy compositions specifically designed for lightweighting, ductility, durability and thin-walled parts.
Our extensive on-site heat-treatment facility is equipped with a large solution furnace, measuring 11.56m³ (2.15m x 2.15m x 2.5m), allowing us to treat large castings and significantly improve their mechanical and physical properties. Our specialist heat treatment team utilise a range of water and polymer quench to control distortion and residual stress in all castings according to customer requirements.
At Finecast, we utilise the latest cutting-edge optical scanners (GOM/Creaform) to inspect and validate our castings for dimensional accuracy and stability. Our process begins by creating a 3D model that is precisely overlaid on the original part CAD model. This allows us to align the casting and machining data points for consistently accurate machined castings.
Our specialist quality team utilise our state-of-the-art GE Seifert X|Cube 320KV CT Scanning System, a powerful tool for attaining the highest levels of non-destructive testing (NDT) and quality assurance for integrity critical motorsport castings. Offering unparalleled accuracy and reliability, this system uses advanced radio tomography and computer tomography scanning technology to identify microporosity, small incipient cracks, and surface imperfections quickly and accurately. This enables us to guarantee high-integrity castings every time, in accordance with our customer’s requirements and expectations.
The integrity of our motorsport castings is guaranteed through advanced air decay and hydrostatic pressure testing. These tests enable us to thoroughly check complex components with intricate oil galleries, such as engine blocks and cylinder heads, by repeating multiple leak rates and test pressures.
CNC Machining for Motorsport Sand Castings
Our machining division is equipped with highly advanced 5-axis Mazak CNC machining centres and driven turning machine tools, providing a fully integrated service. This state-of-the-art machinery enables us to create components of high precision and complex geometries with repeatable accuracy.
Our team has extensive experience in machining a wide range of complex cast products for the motorsport industry such as engine blocks, cylinder heads, gearbox housings, turbochargers, battery trays, electric drive units and structural BiW parts in a range of different materials including aluminium, copper and nickel alloy and specialist steel and iron.
Dimensional Validation for Motorsport Sand Castings
Our in-house metrology laboratory is fully equipped with the most advanced inspection and validation technology, including three state-of-the-art coordinate measuring machines (CMM) and programmable probe stations able to accurately measure components up to two metres in size.
In addition, we also have Hobson Taylor Talysurf inspection instruments for surface finishes, contours and angle measurements.
By utilising the latest CMM technology, our team of highly experienced metrologists are able to guarantee highly accurate machined castings that meet our customer’s requirements and provide comprehensive CPK Indices, SPC analysis, full ISIR and FAIR reports as part of our quality assurance process.
View A Selection of our Latest Projects
Motorsport Engine Block
Material: Alluminium A357
Dimensions: 500x400x225mm
Weight: 11Kg
Quantity: 100
Delivery: MAGMASOFT simulation mould pack development, initial batch manufactured from printed moulds, 4 working weeks. Production batches from a full suite of tooling 9 working weeks.
Motorsport Engine Block
Material: Alluminium A357
Dimensions: 500x400x85mm
Weight: 8Kg
Quantity: 100
Delivery: MAGMASOFT simulation mould pack development, initial batch manufactured from printed moulds, 4 working weeks. Production batches from a full suite of tooling 8 working weeks.
Motorsport Cylinder Head
Material: Alluminium A357
Dimensions: 500x400x185mm
Weight: 10Kg
Quantity: 100
Delivery: MAGMASOFT simulation mould pack development, initial batch manufactured from printed moulds, 4 working weeks. Production batches from a full suite of tooling 9 working weeks.
5 Phase Transmission
Material: Aluminium Alloy A356
Dimensions: 449mmx439mmx443mm
Quantity: 12 pieces
Delivery: Rapid prototype castings from sand-printed moulds fully machined in 8 weeks.
Chassis BiW Casting
Material: Aluminum Alloy A356 Refined Alloy
Mechanical Properties: UTS:270MPa, 0.2 Proof Stress 210Mpa & Elongation 11%
Dimensions: 1280mmx340mmx680mm XYZ. Internal complete geometry hollow for reduced component weight produced by 3D rapid prototype sand printed high strength internal core
Cast Wall Section: 3mm consistent complete casting
Cast Weight: 19 Kg
Quantity: 80 pieces
Delivery: First delivery finished cast components includes TiZr coating 12 w14 weeks from bridging sand cast tooling
Front BiW Casting
Material: Aluminum Alloy A356 Refined Alloy
Mechanical Properties: UTS:MPa, 0.2 Proof Stress 210Mpa & Elongation 11%
Dimensions: 855mmx530mmx690mm XYZ
Cast Wall Section: 3.5 mm consistent complete casting
Cast Weight: 14 Kgs
Quantity: 50 pieces
Delivery: First delivery finished cast components includes anodise and Ppac nut assembly 14 weeks from bridging sand cast tooling
Drain Trough BiW Casting
Material: Aluminum Alloy A356 Refined Alloy
Mechanical Properties: UTS:180MPa, 0.2 Proof Stress 110Mpa & Elongation 10%
Dimensions: 470mmx513mmx417mm XYZ
Cast Wall Section: 2.5 mm consistent complete casting
Cast Weight: 2.8 Kgs
Quantity: 50 pieces
Delivery: MAGMASOFT simulation casting development, Foundry tooling with first produced casting 6 weeks
Battery Tray BiW Casting
Material: Aluminium A356 Refined Alloy
Mechanical Properties: UTS: 260MPa & Elongation = 12%
Dimensions: 580mmx656mmx560mm
Cast Wall Section: 2.5mm complete casting
Cast Weight: 3 Kgs
Quantity: 810 pieces
Delivery: First casting batch 6 weeks including machining and assembly
Shock Tower BiW Casting
Material: Aluminium A356 Refined Alloy
Mechanical Properties: UTS: 189MPa & Elongation =18%
Dimensions: 360mmx310mmx340mm
Cast Wall Section: 2.5mm complete casting
Cast Weight: 3.4 Kgs
Quantity: 120 pieces
Delivery: MAGMASOFT simulation casting development, Foundry tooling with first produced casting 6 weeks
Bracket BiW Casting
Material: Aluminium A356 Refined Alloy
Mechanical Properties: UTS:180MPa, 0.2 Proof Stress 110Mpa & Elongation 10%
Dimensions: 479mmx408mmx471mm
Cast Wall Section: 3mm complete casting
Cast Weight: 2.3 Kgs
Quantity: 120 pieces
Delivery: MAGMASOFT simulation casting development, Foundry tooling with first produced casting 6 weeks
Shock Tower BiW Casting
Material: Aluminum Alloy BS L99
Mechanical Properties: UTS:230MPa, 0.2 Proof Stress 190Mpa & Elongation 5%
Dimensions: 475mmx430mmx579mm
Cast Wall Section: 3.5mm complete casting
Cast Weight: 10.1 Kgs
Quantity: 120 pieces
Delivery: MAGMASOFT simulation casting development, Foundry tooling with first produced casting 6 weeks
Working in Partnership with World Leading Companies
