Hallam Castings is a leading UK manufacturer of high-quality aluminium castings, specialising in high pressure, gravity and sand castings as well as cast wound rotor cores. With decades of experience supporting OEMs and tier-one suppliers across a range of industries, Hallam Castings combines technical precision with a deep understanding of complex design requirements.
Our commitment to engineering excellence, continuous improvement and customer focus has established us as a trusted partner for clients across Medical, Marine, Electrical, and Industrial sectors.
Services
In the heart of Yorkshire Hallam Castings was founded by my Grandfather and Father, Wilf and Derek Hallam in the late 60’s, whose journey began in the engineering diecasting department of Associated Electrical Industries (AEI) later known as GEC, where Wilfred was the diecasting department manager. After leaving the Royal Engineering Corp when his national service ended, Derek joined Wilfred as diecasting foreman. Their early work at AEI/GEC involved casting rotor cores, stators and endshields for motors used primarily in white goods — a craft they would go on to master and specialise in.
From these humble beginnings, rotor diecasting became the cornerstone of Hallam Castings’ operations. At the height of production, the company was casting an impressive 250,000 rotor cores per month, supplying a wide range of motor manufacturers such as Torin Sifan, Mellor Electrics, EMD, GB Electronics, Brook Crompton Motors, Regal Beloit, Ashwoods, DANA, to mention just a few.
Over the years, we’ve produced countless rotor variants — finned and non-finned, open and closed slot, standard, high, and low resistance endrings, as well as skewed, straight, and chevron skewed rotors, broaching, reaming or burnsihing bores, mounting counterbalace weights and grinding/turning ODs.
Our deep collaboration with lamination manufacturers has given us extensive experience in tackling challenges such as material wedging, lamination burrs, and insulation issues.
With decades of hands-on expertise and a legacy rooted in precision and innovation, it’s fair to say: we know a thing or two about rotor diecasting.
Hallam Castings has grown from a traditional foundry into a modern manufacturing business with a reputation for quality and reliability.
Building on a strong heritage in aluminium casting, the company has evolved over the years by investing in advanced technology, improving processes, and developing long-standing customer relationships. Today, Hallam Castings continues to deliver value through innovation and a deep-rooted passion for British manufacturing.
Our facility is strategically positioned with exceptional transport links, situated close to the M18 motorway – a vital link road connecting directly to the UK’s main arterial networks, the M1 and M62 motorways. This prime location provides us with unparalleled access to major industrial centres across the UK, enabling efficient distribution and reducing lead times for our customers throughout England, Scotland, and Wales.
Our proximity to these major transport corridors means we can offer:
• Rapid delivery to customers across the UK
• Seamless connections to major ports and airports
• Reduced transportation costs and environmental impact
• Flexible logistics solutions tailored to your requirements
Global Partnerships & International Capabilities
We understand that modern manufacturing demands global solutions. That’s why we’ve cultivated strong partnerships with trusted international shipping specialists who can freight our products to any destination worldwide. Whether you need components delivered to Europe, the Americas, Asia, or beyond, our logistics network ensures your orders arrive safely and on schedule.
Our international shipping partners provide:
Operating from a well-equipped facility in Doncaster, Hallam Castings houses a modern foundry with multiple casting cells, high-specification CNC machining centres, automated powder coating plant as well as advanced quality control equipment. The site is designed for flexibility and efficiency, enabling short lead times, batch scalability and consistent product quality. From dedicated tooling areas to in-house finishing and assembly capabilities, the factory layout supports streamlined production and a rapid response to customer demand.
Hallam Castings maintains the highest levels of quality throughout its operations, holding BSI ISO 9001 & 14001 certification as well as EcoVadis accreditation, we also continually invest in systems and processes that ensure full traceability, repeatability and compliance. With a focus on precision and consistency, all castings undergo rigorous testing and inspection – including dimensional verification and pressure testing where required. The company’s proactive approach to quality management underpins its reputation for excellence and its ability to meet the critical demands of global markets.
We don’t just promise precision—we prove it. Our quality assurance process is built around industry-recognised standards and tools, including:
At the core of Hallam Castings is a highly skilled engineering team with extensive experience in the design and production of complex aluminium components. Their knowledge spans every stage of the casting process – from initial concept and tooling development through to final inspection and delivery. With a practical understanding of materials, tolerances and manufacturing constraints, Hallam’s engineers are able to support customers in refining product designs, improving manufacturability, and reducing overall costs without compromising on quality. This depth of engineering expertise ensures a collaborative, solutions-led approach that adds value from the outset and supports long-term technical partnerships.
