Sand Casting
We are uniquely positioned as the only UK foundry specialising in producing technically challenging thin walled sand castings in all aluminium alloys and a wide range of specialist iron and steel grades.
Our integrated foundry facilities are configured to support you with upfront casting MAGMASOFT engineering and design support, rapid prototype production intent castings manufactured by the latest foundry 3D tool-less sand printing additive technology. Scheduled low volume production of up to 5000 units can be manufactured in our purpose-built automated series foundry for components typically up to 2.5 metres in size.
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Discuss your project with a casting development engineer
Aluminium Alloy Castings
At Finecast Foundry, we specialise in producing high-integrity, complex aluminium alloy castings for a variety of industries, including automotive, motorsport, aerospace, and defence.
We have the capacity to manufacture aluminium castings ranging from 100mm to 2.5m, with a maximum weight of 900kg and a minimum wall thickness of 2.5mm.
Providing a fully integrated solution ensures exceptional mechanical integrity and dimensional accuracy for each and every casting we manufacture. Our casting manufacturing process includes casting design, virtual casting simulation, 3D sand printing, pattern tooling, semi-automated mould assembly and pouring, metallurgy testing and analysis, heat treatment, non-destructive testing, CNC machining, and CMM dimensional validation.
We cast a wide range of aerospace and commercial aluminium alloys. Additionally, we specialise in developing high-integrity copper and nickel-based castings, ideal for naval and defence applications requiring corrosion resistance. To view our complete list of aluminium alloys, see our technical engineering guide.
Whether you require rapid prototyping, small batch, or production volumes, our skilled team is committed to delivering high-integrity, fully machined, aluminium cast components exactly to customer specifications.
Specialist Iron & Steel Castings
Our experience producing castings is not limited to aluminium alloys. Our capabilities and expertise extend to manufacture of iron and steel alloys including the complete ductile range of SiMo, Ni-Resist, Austenitic irons and Stainless-Steel Grades to 300 kg weight. To view our complete list of iron and steel grades click here.
The experience of our metallurgists and ferrous methods engineers ensures that each product is engineered to meet their material and design specification. The application MAGMA Ferrous & Iron simulation software with years of applied process knowledge of using multiple sand medias with high thermal efficiency and permeability, refactory coatings to produce exacting repeatable dimensionally accurate castings with a surface finish of 4Ra.
Our internal heat-treatment and extensive materials laboratory ensures that casting product are processed and qualified to your specification. Within our laboratory spectrograph chemical analysis, microstructure and tensile mechanical testing is performed by a dedicated team of metallurgist MA qualified.
Rapid Prototype Castings
Our reputation as the prototype casting leader has been built over years of successfully demonstrating repeatable rapid delivery of superior quality, technically challenging components.
Integrated in-house management of all process within our purpose-built prototype foundry includes for Voxeljet additive manufacturing sand printing, high speed foundry tooling manufacture and the latest computer tomography and digital 3D scanning technology for product qualification guaranteeing only the highest quality without compromise delivered rapidly in days.
Complete 3D mould packages or hybrid tooled assembles with complex geometry cores can be in both a synthetic and silica medias to an accuracy of +/- 0.3mm producing highly dimensionally consistent castings conforming to DCTG7 casting dimensional tolerances.
The ability to print in differing sand medias allows for a suitable and cost-effective method of producing aluminium and iron alloys from silica and synthetic sand for higher temperature alloys or applications requiring high thermal stress condition or requiring improved cast surface finish for performance.
Lightweight Engineering
Working in partnership with leading global OEM’s, Universities and Casting Industry Intuitions, we are pioneering the development and manufacture of lightweight high strength aluminium structural components.
From extensive research & development, we have pushed the boundaries of sand cast components producing the consistent wall thickness of 2.5mm on structural BiW (Body in White) components up to 2.5m in length.
To support material innovation towards lightweight powertrain and body structure, we have refined high silicon aluminium alloy series to prototype and low volume sand cast production replicating the geometry and mechanical properties of series High Pressure Die Castings HPDC. From high ductility to high strength elongation of 18% with UTS of 300 MPA.
We are at the forefront of new material evaluation after undertaking development and manufacturing components in A2xx aluminium series aluminium. Lightweight structures can now be produced repeatable with mechanical properties of carbon steels offering a sustainable and economical alternate to forging and fabrication of aluminium and steel.
Prototype & Production Foundry
Our purpose-built designated prototype and production foundry offers flexibility to support rapid prototyping, initial production phase builds and scheduled production volumes up to 5000 units.
Our foundry supports the production of components where high cast and mechanical integrity, as well as surface finish quality, are imperative, predominantly for the automotive, motorsport, aerospace, and defence industries.
Investment into the latest foundry equipment including semi-automated mixers, high speed mould filling and closing stations offer repeatable processing efficiencies for components up to 2 msq. Thermal reclamation of sand improves mould quality of a consistent cast tolerances of +/- 0.2mm and excellent surface finishing ranging from 2RA to 6 RA dependant on size. This method of sand reclamation offers cost benefits and is environmentally sustainable as 95% of the sand is reclaimed.
Onsite heat-treatment facilities allow for large components to be processed to international or bespoke conditions. To conform to Aerospace standards and full traceability of product heat-treatment ovens are fitted with probe installation to record and temperature and cycle times.
View a selection of our latest casting projects
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
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
BiW Casting
Material: Aluminum Alloy A356 Refined Alloy
Mechanical Properties: UTS:180MPa, 0.2 Proof Stress 110Mpa & Elongation 10%
Dimensions: 875mmx466mmx365mm XYZ
Cast Wall Section: 3mm consistent complete casting
Cast Weight: 4.1 Kgs
Quantity: 50 pieces
Delivery: MAGMASOFT simulation casting development, Foundry tooling with first produced casting 6 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.
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
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.
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
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.
Central Node BiW Casting
Material: Aluminium A356 Refined Alloy
Mechanical Properties: UTS:290MPa, 0.2 Proof Stress 210Mpa & Elongation 4%
Dimensions: 1026mmx473mmx362mm XYZ
Cast Wall Section: 4mm consistent complete casting
Cast Weight: 39 Kgs
Quantity: 50 pieces
Delivery: MAGMASOFT simulation casting development, Foundry tooling with first produced casting 6 weeks
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
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
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.
Material grades cast at Finecast
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