Rapid Prototyping Facility

Rapid prototyping uses 3D computer-aided design (CAD) and manufacturing processes to quickly develop 3D parts or assemblies for research and development and/or product testing.

We are able to 3d print your prototype tooling, to be able to provide a fit for function casting within a very short space of time eliminating the expense and delays of tooling modifications.

Rapid Prototyping of Castings
Aluminium Armament Castings & Brackets Foundry

Powder Coating for Aluminium Castings

The ability to arrange for paint finishing, along with powder coating, anodising and polishing means that, as part of our commitment to a total solution, Foundry & Fabrication are able to supply completely finished parts to your assembly line. Aluminium cast parts can be put through a number of pre-treatment processes to prepare them for paint finishing, with either powder coating or wet spraying techniques.

Powder coating produces a hard-wearing finish that is tougher than conventional paint and is often preferred for industrial products. The paint is applied as a free-flowing powder attracted to the metal by means of an electrostatic charge – all over the metal to ensure complete coverage. The process is then finished off by heating the powdered part in an oven to melt the powder forming a solid durable skin.

Whichever paint finishing method you opt for; Foundry & Fabrication can ensure the best possible results for your aluminium casting using high-quality local sub-contract paint finishers.

Powder Coating Castings

Vacuum Impregnation

Even with the best materials and equipment, operated by skilled professionals and to the highest standards, the designs of some aluminium castings can be prone to slight imperfections within the cast parts.

Shrinkage can result in sponge porosity, which can result in occasional issues with leakage through the casting walls. To prevent this, a process called vacuum impregnation can be used to seal the castings.

A commonly used practice in automotive castings, it is becoming more popular within general castings to eliminate the need for 100% pressure testing of parts. The resin used in the process is introduced under pressure and once cured forms a solid seal unaffected by petrochemicals.

Impregnation Section
castings for construction

Aluminium Heat Treatment

Sometimes, to get the best results with your aluminium casting, it is necessary to alter the physical properties of the metal alloys being used. Using heating and cooling (or quenching) processes, we can soften or harden the materials used in our aluminium foundry until they are suited to subsequent processing. Most often used to increase the strength of an alloy, it can also aid the machinability of the castings to improve finish machining tolerances.

Heat treating requires precise control over temperature to achieve the desired results, as it is important to make sure that the aluminium alloy remains within an exact temperature range for the correct length of time, and cools at the proper rate. We have 3 ovens on site, which gives us great capacity for even the highest production demands.

Sand Castings Manufacturing UK

Plating and Polishing of Aluminium

Anodising and allochroming can be used to protect the surface of aluminium castings from subsequent corrosion, especially where corrosive elements such as seawater are common.

Polishing can be an important part of the finishing process for your sand casting and can be arranged as part of Foundry & Fabrication’s total solution for your aluminium casting needs.

Polishing can be required as part of an aesthetic or a surface finish requirement before a range of finishes can be offered.