full

Aluminium Diecasting and CNC machining

Hallam’s internal manufacturing capability includes high pressure, sand and gravity aluminium diecasting, CNC machining, CNC powder coating, assembly to final product stage and full function, safety and quality testing.

+44 (0)1405 813006REQUEST A QUOTE →

full

Concept Development & Product Design

Hallam’s current year Solidworks Professional CAD system facilitates the exchange of design files with customers development teams in a wide range of formats.

+44 (0)1405 813006REQUEST A QUOTE →

full

Prototype Production

Hallam can apply a wide range of resources internally to the manufacture of prototypes following concept finalisation, initial DFM and computer simulation phases.

+44 (0)1405 813006REQUEST A QUOTE →

full

Component Sourcing

Ferrous castings, polymer or metal extrusions, injection moulded and laser cut metal parts, mechanical sub-assemblies and electrical components can all be outsourced across Hallam’s extensive network of suppliers.

+44 (0)1405 813006REQUEST A QUOTE →

full

Volume Assembly & Despatch

Hallam now offers a genuine 'one stop' solution for many customers looking for component sourcing and final assembly.

+44 (0)1405 813006REQUEST A QUOTE →

full

Powder Coating Services

Our powder coating plant benefits from our manufacturing expertise in many ways. For example, the special carousels and housings needed to suspend components through the plant are designed and manufactured by us.

+44 (0)1405 813006REQUEST A QUOTE →

full

World Class Product Design, Manufacture and Assembly Services

+44 (0)1405 813006REQUEST A QUOTE →

WHAT WE DO

Aluminium Diecasting and CNC Machining
Aluminium Diecasting and CNC Machining

View Our Services

Component Sourcing
Component Sourcing

View Our Services

Concept Development & Product Design
Concept Development & Product Design

View Our Services

Volume Assembly & Despatch
Volume Assembly & Despatch

View Our Services

Prototype Production
Prototype Production

View Our Services

Powder coating services
Powder coating services

View Our Services

Aluminium Pressure Die-casting with In-house Machining,
Powder Coating and Advanced Design Support

Hallam Castings is a long-established aluminium die-casting specialist manufacturer based near Sheffield in South Yorkshire also offering a wide range of design-for-manufacture and prototyping services. Hallam offers high pressure diecasting across a range of 8 German “Frech” machines capable of producing castings weighing up to 6 kg, together with CNC machining on 6 DMG Mori and Victor machining centres and lathes as well as in-house fully automatic powder coating. Hallam can also design ancilliary components for customers as extrusions, injection mouldings or fabrications using Solidworks Professional Computer Aided Design (CAD) software. CAD models can be converted to resin, silicon, polymer or metal prototypes quickly and cost effectively.

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
     

WHY CHOOSE HALLAM CASTINGS?

Under NDAs, Hallam Castings product design team have developed close working relationships with our customers’ own designers and the team is consulted at an early stage during the product design or re-design process. Hallam Castings can provide advice not only on technical constraints but also on design-for-manufacture and product assembly issues.
Hallam Castings competes in global markets and many of our customers are multi-national organisations. Hallam’s prices are often lower than Far Eastern or Eastern European prices and always offer better value-for-money.
Hallam Castings are positioned uniquely as an expert and reliable product design and manufacturing partner of the highest integrity, offering excellent value-for-money and access to the highest level of technical expertise in all manufacturing areas.
Contact Managing Director Rob Pickersgill directly on 07983 315292 anytime to discuss your project requirements.

Our services include Concept Development, Aluminium Castings, Product Design, Manufacturing, Component Sourcing, Volume Assembly, and Dispatch.

WHAT CLIENTS SAY ABOUT US

“CTD have worked with W Hallam Castings for many years, initially as a supplier of cast aluminium housings, and it is clear that the company has evolved to become a manufacturing partner with exceptional knowledge and capability not only within the castings area but in relation to design, sourcing and assembly of manufactured products generally.”

Richard Turpin
Control Techniques Dynamics, Emerson Group

HALLAM CASTINGS ARE MEMBERS OF THE CAST METALS FEDERATION

CLIENTS WE WORK WITH