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