Aluminium Die Casting & CNC Machining
UK Aluminium Casting services
At Hallam Castings, we adhere to the stringent ISO 9001:2015 and ISO 14001 quality standards. These certifications, awarded and audited annually by the British Standards Institute, reflect our commitment to excellence. Our Quality and Health and Safety Managers collaborate closely at every level of production, ensuring our aluminium casting processes meet the highest achievable standards. We employ Six Sigma methodologies, including Ppk and Cpk analysis, to ensure precision and consistency in both new and ongoing production runs. As one of the premier UK manufacturers of aluminium castings , our dedication lies in delivering top-quality aluminium casting products.
Aluminium Die Casting Machinery and Equipment
Hallam Castings manufacturing capability includes sand, gravity and high pressure die casting in aluminium and zinc alloys; CNC machining; fully automated powder coating; assembly of manufactured and outsourced components to create complete products and sub-assemblies.
Our aluminium casting capabilities encompass a variety of techniques, including aluminium sand casting, gravity casting, and high-pressure die casting using aluminium and zinc alloys. We also offer CNC machining, automated powder coating, and the assembly of fabricated and purchased components into ready-to-use products and sub-assemblies. Our aluminium die casting machines are engineered for precision, injecting molten aluminium under high pressure into hardened steel moulds. This method allows for the creation of complex shapes with high precision and short production cycles, making it ideal for large-volume orders. As one of the top aluminium casting suppliers, we ensure that our custom aluminium castings conform precisely to our clients’ requirements.
We specialise in cold chamber high-pressure aluminium die casting, guaranteeing tolerances of +/- 0.1 mm and wall thicknesses as thin as 1.5 mm. This method produces aluminium parts with fine surface finishes that can withstand extreme pressure and heat. Our pressure die casting dies are designed for long-lasting, high-performance operations. However, careful mould design is crucial to prevent porosity in the parts, a common issue in pressure die casting compared to aluminium sand casting or gravity casting. Following simulation of metal flow within the casting mould we strategically place vents in our castings to eliminate trapped air, ensuring the highest degree of precision in our aluminium castings.
CNC machinery is supplied and maintained by DMG MORI. Hallam uses CAMWORKS to interface Solidworks Professional CAD models with its CNC equipment.
The UK company Haviland designed and constructed Hallam’s powder coating plant specifically for the surface finishing of aluminium components and products. The plant included a five stage pre-treatment unit and Saracen gas fired recirculating conveyerised oven. The aluminium castings plant can accommodate components weighing up to 10 kg and one metre in height or diameter.
How Aluminium Die Casting Works
In aluminium die casting, molten aluminium is injected at high pressure into a steel die. Once the metal has solidified, the die opens, and the part is ejected. This process, completed in fractions of a second, allows for the production of hundreds of casts per day. The efficiency of this process makes it highly economical for large-scale production of custom aluminium casting products. As a leader in the aluminium die casting industry, Hallam Castings has made significant investments in modern equipment to maintain the highest quality standards for every item produced.
Benefits of Using Our Aluminium Casting Services
At Hallam Castings, we utilise advanced CAD models to develop tooling that minimises air entrapment, enhancing the quality of our aluminium castings. Our collaboration with the University of Sheffield Advanced Manufacturing Research Centre has deepened our understanding of porosity prevention. Our manufacturing capability is based on high-pressure die casting machinery from the world’s leading die casting machine manufacturer Frech Germany, connected online for fault finding and efficiency monitoring. Across two shifts our capacity is more than 30,000 die casting hours per year. Our DMG MORI-supplied CNC machinery works seamlessly with our Solidworks Professional CAD models via CAMWORKS to ensure accuracy at every stage of the production process from aluminium casting to finished product assembly.
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Process methods – Lean Six Sigma
“Lean Six Sigma is a business approach to continual improvement which focuses on stripping out areas of waste from processes and minimizing product reduction. Lean refers to maximizing customer value and minimizing waste; creating more value for customers with less wasted resources. Six Sigma is the on-going effort to continually reduce process and product variation through a defined project approach” – British Standards Institute
Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in a manufacturing (or service) process.
The fundamental objective of the Six Sigma methodology is the implementation of a measurement-based strategy that focuses on process improvement and variation reduction through the application of Six Sigma improvement projects.
The Six Sigma DMAIC process (define, measure, analyze, improve, control) is an improvement system for existing processes looking for incremental improvement.
The Six Sigma DMADV process (define, measure, analyze, design, verify) is an improvement system used to develop new processes or products at Six Sigma quality levels.
Hallam Castings adopts Lean Six Sigma principles in all its manufacturing and administrative operations and embeds these alongside Quality and Health and Safety principles and rules in creating a fully integrated operational culture. Hallam Castings recognises that quality control, quality improvement, safety and process improvement are inextricably linked objectives.
Benefits of Aluminium Casting
The aluminium die casting method enables the mass production of components with low tolerances and excellent surface finishes. This process offers numerous benefits for manufacturers, including the ability to produce intricate shapes quickly and cost-effectively. At Hallam Castings, our expertise and advanced aluminium die casting machines allow us to meet even the most stringent quality requirements. Our aluminium die casting products are engineered to endure high stress and temperature conditions, making them ideal for demanding applications.
Top UK Aluminium Casting Manufacturers
Hallam Castings is proud to be one of the UK’s leading aluminium casting manufacturers. As pioneers in technology, we also operate a Haviland-designed powder coating plant capable of handling components weighing up to 10 kg and measuring up to one metre in height or diameter. Our commitment to Lean Six Sigma drives a continuous process of improvement, reducing waste and consistently enhancing the quality of our products. As a major aluminium casting supplier in the UK, we are dedicated to exceeding our clients’ expectations by providing innovative aluminium die casting solutions.
Case studies
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FAQ
High-pressure die casting provides a high quality surface finish and closer surface tolerances with low unit cost while aluminium sand casting can be more advantageous in low-volume runs with less complicated forms or moulds.
We design our moulds to include well-planned, strategic vents and use dynamic CAD models providing metal flow simulation to ensure that air is efficiently displaced in the die casting process.
Our aluminium die casting machines and advanced process capabilities allow high volume production with high efficiency, so our company is a key supplier of aluminium castings in the UK.
Hallam Castings further guarantees that all quality control, safety, sustainability and process improvement objectives in both our manufacturing and administrative operations are fully met through the application of Lean Six Sigma methodologies, which places us in a leadership position in the UK aluminium die casting industry.
