Technical Engineering Guide
Finecast Foundry specialises in manufacturing complex, high-integrity cast components in all aluminium alloys and a wide range of specialist iron and steel grades. Explore our technical engineering guide for a comprehensive insight into our sand casting processes, expertise and capabilities.
Material Grades Cast
Finecast casts a wide variety of ferrous and non-ferrous materials, including all aerospace and commercial aluminium alloys, a full range of austenitic stainless steels for heat, wear, and corrosion resistance, as well as nodular SG iron, flake and austenitic graphite irons, and non-ferrous copper-based alloys.
Casting Design & Engineering
Casting Design
Industry-leading CAD resources enable specialist CAD engineers to work directly from raw component native data in STEP, CATIA, Pro E and SOLIDWORKS files.
The raw casting model is optimised, adding machining allowance, radii and draft allowance and gating system.
Complete 3D casting and machined models can be generated from 2D drawings if no 3D data is available.
Reverse engineering from existing components is provided using CMM optical scanners and computer tomography capabilities to produce 3D datasets for casting and machining.
Virtual Casting Simulation
MAGMASOFT 32CORE virtual casting simulation capabilities ensure that the method is qualified “right the first time,” eliminating the need for lengthy sample trials and significantly reducing development costs and lead times.
Simulation capabilities include mould fill and solidification, mechanical properties predictions for aluminium, steel, and iron castings, and residual stress predictions in both the as-cast and heat-treated conditions.
Through virtual simulation, specialist method engineers develop and qualify an optimised 3D casting model, including the sprue, runner, in-gate and riser system, ready to incorporate into the mould assembly package design.
Mould Assembly Package Design
Based on the complete, fully validated 3D casting model, an optimised mould assembly package is created, complete with precise split lines, core layouts, and clearances that are dimensionally accurate and repeatable.
Mould assembly design can be simplified by utilising 3D sand printing technology, enabling the consolidation of multiple intricate cores into a unified printed piece.
Consolidating the number of complex cores enhances efficiency, accuracy, and repeatability, while also reducing assembly time. This results in higher quality and more cost-effective manufacturing of complex cast components.
3D Sand Printing
3D Sand Printing Technology
The In-house additive manufacturing facility, equipped with cutting-edge Voxeljet 3D sand printers, enables the rapid production of complex cast components within just days instead of weeks.
Voxeljet Universal Binder Jetting (UBJ) 3D printing technology allows for the rapid manufacture of complex moulds and cores, eliminating the need for expensive pattern tooling, as well as offering complete design freedom, the realisation of undercuts, greater accuracy, and improved repeatability.
Sand Media
Voxeljet 3D sand printers provide the flexibility to print using a wide range of sand media, from silica sand to thermally efficient synthetic sands like Cerabeads®.
This versatility enhances casting design, surface finish, and tolerances, while also providing the ability to cast in ferrous and non-ferrous materials, from low-temperature aluminium alloys to high-temperature iron and steel alloys.
Mould/Core Sizes & Capacity
Complex sand moulds and cores, measuring up to 1800 x 1000 x 700 mm, can be rapidly manufactured directly from customer data within days of receipt.
3D sand printing facilities support rapid prototyping, small-series production, and medium-series production volumes.
Additionally, 3D sand printing enables the option of hybrid pattern tooling incorporating 3D sand printed cores.
Tolerances & Surface Finish
Close tolerance 3D sand-printed moulds and cores can be manufactured in silica or synthetic sand media, achieving an accuracy of ±0.3 mm.
This capability facilitates the production of castings with highly consistent dimensional accuracy, conforming to DCTG8 casting dimensional tolerances.
Providing exceptional surface finishes of 4RA (aluminium) and 5-7RA (iron, steel, and bronze).
Pattern Tooling
CNC Machining
Technology
In-house pattern tooling facilities include multiple CNC machines for high-speed multi-axis milling of pattern tooling, operating 24 hours a day for rapid turnaround.
Industry-leading Delcam CAM software is utilised to offline program, allowing for reduced engineering and cycle times.
Should component redesign be required, modifications can be quickly and accurately adapted.
Pattern Tooling
Materials & Quantities
Pattern tooling is produced from a range of polyurethane resin density grades:
Low grade with a typical casting quantity of 250 units.
Medium grade with a typical casting quantity of 2500 units.
High grade with a typical casting quantity of 6000 units.
Aluminium cut patterns are also produced with a typical casting quantity of 7000-8000 units.
Pattern Tooling
Sizes & Capacity
Pattern tooling facilities allow for machine-cut, dimensionally consistent pattern equipment and fixtures up to 2000 x 1000 x 420 mm in size.
Providing the capacity to support prototype, small batch, and scheduled production foundry tooling for casting volumes of up to 8000 units.
On-site capability of 3D sand printing provides the option of pattern tooling and hybrid tooling with 3D printed cores.
Pattern Tooling
Tolerances
Specialist pattern makers use advanced tooling technology to manufacture precision pattern tooling with a tolerance of +/- 0.1mm.
This ensures the production of high-quality, dimensionally accurate, and consistently repeatable sand castings that meet customer specifications.
Prototype & Production Foundry
Foundry
Technology
The Prototype and production volume foundry features the latest cutting-edge equipment, including automated mixers, high-speed mould filling, and closing stations, ensuring repeatable processing efficiencies.
Various sized melting furnaces enable the melting and pouring of different alloys to meet specific project requirements.
ATAS (Adaptive Thermal Analysis System) MetStar controls the metallurgical process, analysing, stabilising, and optimising casting production.
Utilising the latest OMEGA thermal reclamation technology, up to 95% of foundry sand is reclaimed.
Material Grades
Cast
Sand Castings are manufactured from an extensive range of ferrous and non-ferrous materials.
Including all aerospace-grade and commercial aluminium alloys, a comprehensive selection of austenitic stainless steels engineered to resist heat, wear, and corrosion, as well as nodular SG iron, flake and austenitic graphite irons, and various non-ferrous copper-based alloys.
Through continual metallurgical control, castings meet the strict metallurgical requirements of industries such as automotive, motorsport, defence, aerospace, space exploration, marine, chemical, nuclear, and rail.
Casting Sizes
Weights & Quantities
Sand castings up to 2.5m² with a minimum wall thickness of 2.5mm can be manufactured with exceptional accuracy and efficiency.
Maximum casting weight is 900 kg for aluminium and 300 kg for iron, steel, and non-ferrous copper-based alloys.
The foundry facility provides the capacity and flexibility to support rapid prototypes, initial production phase builds, and scheduled production volumes up to 5000 units, supporting each stage of the manufacturing journey.
Casting Tolerances &
Surface Finishes
Highly accurate, dimensionally consistent sand castings are manufactured conforming to DCTG7-8 dimensional tolerances.
Superfine surface finishes of 4RA are achieved for aluminium, and 5-7RA for iron, steel, and bronze.
Post Processing & Treatment
Fettling &
Linishing
Post-processing facilities and a skilled fettling and linishing team ensure each casting meets customer requirements. Fettling removes excess material like runners, risers, and flash from sand castings. Linishing smooths and polishes the castings with abrasive belts or wheels, ensuring a refined surface and dimensional specifications are met.
Shot
Blasting
A range of shot blasting machines are used to deburr and clean castings, removing contaminants to prepare them for further processes like painting or powder coating.
This process ensures that these treatments will adhere properly to the castings, enhancing their durability and finish quality.
Heat
Treatment
Heat treatment facilities allow for processing large castings up to 2.5 meters in size to international or bespoke conditions.
To meet aerospace, defence and commercial requirements and ensure full traceability, heat-treatment ovens are fitted with probe installations to record temperature and cycle times.
Surface Treatment
Coating & Painting
Specialist NADCAP-approved coating and painting services offered are specifically designed for the aerospace and defence industries.
These services adhere to strict UK and US defence standards, including DEF Stan and MIL-SPEC, ensuring the highest levels of quality, reliability, and performance for critical applications.
Metallurgical Testing & Analysis
Tensile Testing
Specialist Shimadzu tensile testing machines determine the mechanical properties of ferrous and non-ferrous cast materials, including ultimate tensile strength, yield strength percentage, and elongation percentage up to the point of fracture.
Spectrographic Analysis
Advanced technology spectrometers are utilised for comprehensive chemical composition verification of cast materials, analysing elements such as carbon, silicon, manganese, sulfur, phosphorus, and other trace elements in both ferrous and non-ferrous metals.
Grinding & Polishing
Metallurgical grinding and polishing are performed using OmegaPol preparation systems. Polishing compounds and abrasives are applied to metal samples under controlled conditions to achieve a smooth, defect-free surface ready for microscopic analysis.
Microscopic Analysis
Industry-leading image analysis software is used for microscopic inspection to identify grain size and structure, phase distribution, and microscopic defects in both ferrous and non-ferrous materials.
Hydrogen Analysis
Real-time measurement of dissolved hydrogen in aluminium melts helps identify and prevent hydrogen-induced defects such as porosity and embrittlement, ensuring the integrity and quality of the castings.
Casting Integrity Validation
Digital Radiography &
CT Scanning
The GE Seifert X|Cube Series 320KV X-ray system provides powerful digital radiography and computed tomography inspection, ensuring casting integrity and dimensional accuracy.
Quickly identifying micro-porosity, sand inclusion, sub-surface cracks, shrinkage porosity, and confirms wall thickness, internal core locations, and dimensional stability.
Creaform/GOM Optical Scanning
GOM/Creaform optical scanners are used to map the casting’s external profile and create a 3D CAD model.
The 3D model is compared to the parent data to verify dimensional accuracy and approve batch manufacturing feasibility.
Specialist Machinists then use the 3D model and report to align the casting with set X, Y, and Z coordinates.
Dye Penetrant
Inspection
Dedicated dye penetrant inspection laboratory including immersion tank, wash station, drying oven, storm cabinet and UV inspection station, enables the accurate detection of surface discontinuities like cracks, fractures, porosity, and irregularities in both ferrous and non-ferrous materials.
Ultra Sonic
Testing
Nova TG110-DL ultrasonic thickness gauges are used as a non-destructive testing technique to accurately measure wall thickness, verify uniformity, and determine the depth of internal flaws in hollow cast components with a thickness range of 0.559 mm to 1,270.00 mm.
CNC Machining & Assembly
CNC Machining Technology
The in-house state-of-the-art machining facility is equipped with the latest MAZAK 5-axis CNC machining technology, with the capacity to machine components up to 1.5m cubed.
Specialist machinists utilise Industry-leading Delcam CAM software to offline program, allowing for reduced engineering and cycle times.
Material Grades
Upfront engineering and strong relationships with high-end machine tool providers enable the cutting of almost all ferrous and non-ferrous material grades, including aluminium alloys, iron and steel alloys and copper-based alloys, whether in bar, billet, or casting.
Machining Tolerances
Leveraging modern machining methods and technology, advanced Renishaw probing capabilities, and cutting-edge inspection equipment, provides the ability to achieve and maintain tolerances as precise as 0.005mm.
Assembly & Testing
All aspects of piece part assembly and testing are provided, including pneumatic Böllhoff HELICOIL® and Avdel® insertion, air decay and hydrostatic pressure testing, and industrial-level parts washing.
Metrological Dimensional Validation
Programmable CMM
Verification
The in-house CMM dimensional validation lab is fitted with a range of high-spec programmable CMM probe stations and programming software to accurately measure components up to 2m.
Height Gauge CMM Verification
Surface finish, contour and angle measurements are performed rapidly with accuracy utilising our Trimos V7 and Hobson Taylor Talysurf digital height gauge measuring instruments.
GOM/Creaform Optical Scanning
Portable 3D optical scanning technology provides the ability to scan any type of part, regardless of size, shape, geometry, surface finish, or material to ensure external dimensional accuracy and casting quality through the manufacturing process.
CT & Radiograph Scanning
Powerful X-Ray 2D radiography and 3D computed tomography scanning technology is utilised to capture the internal profiles of castings to guarantee dimensional accuracy in a non-destructive process.
Inspection &
Reports
Advanced CMM technology combined with our highly experienced inspection team ensures that customer requirements are met including CPK Indices, SPC analysis, full ISIR and FAIR reports.
Quality Standards, Certification & Turnaround
Quality Standards
Internal quality frameworks are followed, and designed to meet customer expectations and industry requirements.
We have tier 1 supplier approval for several major automotive, motorsport, aerospace, defence and OEM manufacturers.
Certification
We hold ISO 9001:2015 and EN9100:2018 quality certifications for the manufacture of high-integrity ferrous and non-ferrous machined castings.
As an aerospace EN9100:2018-certified company, we are approved to develop, engineer, and manufacture complex castings to customer design and specification across a wide range of industries.
This scope encompasses tooling design, casting, and verification services, including heat treatment, finishing, radiography, non-destructive testing (NDT), machining, and sub-assembly.
Super Fast Turnaround
Finecast delivers fully machined, cast components for a range of industries worldwide.
Project lead time is highly dependent upon size and complexity, however, we have a typical lead time of around 2/3 weeks for first-off 3D sand printed mould castings and an additional 2/3 weeks for machined castings.