Hallam Castings is a leading business to business manufacturing company located near Sheffield in South Yorkshire. High-pressure die casting is one of a range of services we offer which also include in-house CNC machining and powder coating, combined with advanced design and prototyping support. We specialise in using the latest products and technology in die casting to make highest quality aluminium components for a wide range of industry sectors across the UK and around the world.

In summary, Hallam can help with:

Design and production in-house of cast aluminium components using a variety of alloys offering a range of mechanical properties, together with all associated tooling, with castings machined, surface treated/powder coated and assembled if required, for existing or new products.

Design, prototyping and manufacture of ancilliary components, sub-assemblies or complete new products made up of a range of materials for use in the assembly process.                                 
 
Hallam has helped to design, prototype and manufacture components for many UK companies including:-

• Bisley Office Equipment – “Innerspace” office storage system
• CMD Ltd – “Cygnus” and “Aspect” computer monitor arms
• Function-One – High end PA system loudspeaker
• P4 Fastel – Emergency lighting system

Technical input to other design and manufacturing projects using high quality aluminium castings with other UK-sourced components include:-

Heat sink calculations for new leading edge LED boards incorporated in urban space and industrial lighting systems

Design, prototyping and manufacturing of ratcheting systems to allow the main body cast housing to have variable positioning and load bearing capability.

Design, prototyping and manufacturing of sealing systems requiring research into state-of-the-art gasket materials and special adhesives suitable for attaching the gaskets to the polyesters of powder coated housing body to enhance IP ratings and gain “ATEX” Approval.

Development of novel solutions allowing maintenance access to housings including “pop out” cast sections within the outer wall of a casting, on either side, also allowing either series or individual wiring.

Design, simulation and prototyping of alternative hinging mechanisms in cast housings.
 
Hallam has also undertaken experimental development of new casting alloys and advised on the selection of product materials and finishing treatments based on laboratory testing.

Hallam’s development partners are:-

• Advanced Manufacturing Research Centre, University of Sheffield
• Mercury Centre (additive manufacturing), University of Sheffield
• Department of Mechanical Engineering, University of Sheffield
• University of Wolverhampton
• Cast Metals Federation
• Castings Technology Institute
• DASIS Partners
   

Hallam Castings is a leading business to business manufacturing company located near Sheffield in South Yorkshire. High-pressure die casting is one of a range of services we offer which also include in-house CNC machining and powder coating, combined with advanced design and prototyping support. We specialise in using the latest products and technology in die casting to make highest quality aluminium components for a wide range of industry sectors across the UK and around the world.

Advanced Manufacturing Systems

Hallam Castings uses 8 high-performance German Frech machines that can make aluminium castings weighing up to 6 kg . The company also has six state-of-the-art CNC machining centres for precision machining, toolmaking and prototyping. Hallam also has a fully automatic in-house powder coating unit, ensuring comprehensive services from aluminium casting production through to finishing work that meets the highest standards.

Design and prototype development.

Hallam can design and manufacture a prototype of your new product or component for testing so that it is ready for production, using our SolidWorks CAD software, in resin, polymer, or metal. Encompassing a wide range of client specifications and ideas, we produce custom aluminium casting solutions that meet specific technical and aesthetic requirements.

CNC Machining And High-volume Manufacturing

Hallam Castings provides high-volume CNC machining for industry sectors with a range of production requirements, from die-cast aluminium components to complex assemblies. The company can also assist with guidance in the selection of material and finishing treatment for optimum product performance.

Innovation And Cooperation

Our aluminium casting expertise has enabled us to provide products and components to many UK and European OEMS, including household names like Bisley Office Equipment and Thorn Lighting. We manufacture office equipment and storage systems, leading-edge Hi-Fi and PA systems and urban space lighting and urban activity control system housings utilising complex machined and powder coated aluminium die castings for improved, long-lasting performance. We also collaborate with research organisations, such as the Advanced Manufacturing Research Centre, University of Sheffield to position ourselves at the forefront of new developments in pressure casting materials science.

Hallam Castings’ Services

• Comprehensive design and production services for aluminium components, ranging from tooling to assembly of components using a variety of materials.
• In-house CNC machining and powder coating for a streamlined manufacturing process.
• Prototyping and manufacturing of ancillary components and sub-assemblies.
• Expertise in product design and material selection for optimised production.