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The digital factory tour

Inside the Foundry

Walk the eight stages that turn a drawing into a delivered casting. At every stage you'll see two things: what happens to the casting, and which of our machines makes it happen. That's the whole company in one journey.

STAGE 01 / 08

From drawing to plan

Every casting begins as your drawing. Our engineers review it for how it will actually cast — draft, wall thickness, where metal must feed.

For your castingThe part is assessed for DFM before a single tool is cut.
The machine behind itMachine explorer and tooling data start here — pattern plates are engineered to this drawing.
STAGE 02 / 08

Preparing the sand

Green sand is mixed to controlled moisture and compactability — the single biggest driver of mould consistency.

For your castingConsistent sand means consistent moulds means fewer defects in your part.
The machine behind itOur sand mixer and polygonal sieve keep this sand in spec, batch after batch.
STAGE 03 / 08

Melting the iron

Sorted scrap is charged and melted to target chemistry in induction furnaces.

For your castingThe exact chemistry here sets the grade — grey or ductile — of your finished part.
The machine behind itCharge calculation and melt control are part of the process engineering we also consult on.
STAGE 04 / 08

Confirming chemistry

Before any metal is poured, a spectrometer confirms the chemistry is within grade spec.

For your castingNothing pours until it passes — this is the highest-leverage quality gate in the whole line.
The machine behind itThe discipline of this checkpoint is exactly what our process consulting brings to other foundries.
STAGE 05 / 08

Making the mould

The high-pressure moulding machine compacts sand around the pattern into a dense, dimensionally stable mould.

For your castingHigher, more even mould hardness means your casting holds its dimensions.
The machine behind itThis is our flagship machine — the one you can explore part-by-part on the Foundry Solutions page.
STAGE 06 / 08

Pouring & feeding

Metal fills through a gating system built to fill fast but calm; risers feed the casting as it shrinks solidifying.

For your castingGood gating and feeding is what prevents shrinkage porosity in the finished part.
The machine behind itMould handling systems keep the moulds moving to the pour line in perfect sync.
STAGE 07 / 08

Shakeout, blast & machine

Cooled castings are shaken out, cleaned by shot blasting, and machined to final tolerance.

For your castingCritical features reach the tolerance your assembly needs.
The machine behind itHandling and finishing equipment supports this stage across the shop.
STAGE 08 / 08

Inspect & dispatch

A final dimensional and visual inspection confirms the part is right, then it's packed and dispatched.

For your castingYou receive a casting that was proven correct before it left our floor.
The machine behind itThe whole loop — machine, casting, inspection — is one engineering capability, expressed twice.

You've seen how it's made. Start yours.

Send a drawing to have a casting made — or tell us what equipment your own foundry needs.

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