The Role of Metal Casting Foundries in the UK Economy

Metal casting is an essential part of the UK’s manufacturing pipeline and fulfils a vital role in the creation of an infinite number of products and machines. While this form of manufacturing has existed for centuries, we at Dean Group International have been a contributing foundry for over half a century. As a result, we have seen how much our sector has benefited the UK economy firsthand. Read on to learn what those benefits are for the nation.

Metal Casting’s Role in the UK Manufacturing Supply Chain

Manufacturing is a complex and interconnected series of processes, each one acting as a critical link in the production chain. This vast chain provides immense support for the UK economy as it is estimated by the Manufacturing Technologies Association (MTA) to bring £518bn and 7.3m jobs. Think of it as contributing to 23.1% of the nation’s GDP (gross domestic product) and hosting 22.4% of the job market. Each link in this chain, from the sourcing of materials to the final shipping of completed parts, must function flawlessly to ensure the overall efficiency, quality, and integrity of the manufacturing process.

Metal casting is typically one of the initial stages in the manufacturing process and a foundational one, as it involves turning raw materials into a variety of forms that will be the integral components for sequential manufacturing steps.

Examples of Metal Casting’s Role in Manufacturing

The importance of meeting the required specifications when creating components with investment casting cannot be overstated and demands a reliable quality assurance process. Our cast components are often the structural backbone of the product, machine, or application.

This may not seem as essential for a smaller commercial product, but when you consider our work creating castings for rail, aerospace, and architecture, the demand for reliable results becomes obvious.

Any defects or inaccuracies in the casting process compromise the integrity of the entire production chain. For example, structural weaknesses, poor fitment, and failure under stress are unacceptable problems that will cascade through subsequent manufacturing stages, leading to increased costs, delays, and potentially hazardous product failures. The following are some contextual examples of the importance of metal casting for various sectors.

In the automotive industry, the following are all typically produced through metal casting:

• Engine blocks
• Transmission housings
• Brake components

These components must meet stringent specifications and quality standards to ensure the vehicle operates safely and efficiently. Any deviation in the created parts will create unknown variables that will affect the vehicle's performance and safety.

For the aerospace industry, aluminium castings are used in critical applications such as the following:

• Turbine blades
• Structural supports
• Landing gear

The demand for precision and reliability is even higher in this sector due to the extreme conditions these components must endure. For example, a flaw in a cast turbine blade could lead to catastrophic engine failure.

For architecture, stainless steel castings are a highly popular solution for reliably safe results. Here are some examples of where they are used:

• Decorative mesh façades
• Stadium seat supports
• Roof structural supports

If metal casting foundries did not create parts with reliable results, then many architectural wonders, such as St. Paul's Cathedral, the Angel of the North, and even the gates of Buckingham Palace, would not look the same as they all have cast parts included in their design.

Moving our focus internationally, we managed to see firsthand the importance of architectural castings by contributing to an ambitious project, the Cloud Cities of Barcelona. This permanent addition set on a hill over the city is an interactive art piece where hundreds of visitors must be safe to sit high off the ground on 1,200 polycarbonate panels, and this is only possible thanks to the 6,000 node connectors we created with our die-casting process.

We feel this is an appropriate real-life example as well as a metaphorical example of the vital role of metal casting and the importance of finding a foundry that creates reliably high-quality products. For example, if any of those 6,000 nodes were to fail, then the long-term longevity of this structure would be at risk. There is a reason that this project picked our UK foundry, and it is because of positive reputation that our country’s manufacturing facilities have rightfully earned.

Why Choose UK Casting Foundries?

British manufacturing is synonymous around the world with innovation, quality, and reliability. The source of this reputation comes from the first Industrial Revolution, which presented the UK as a global powerhouse of industrial development and technological advancement, and that has continued to be the case ever since.

Choosing our nation’s domestic metal casting services means businesses gain from the expertise and advanced technologies that have been invested in over decades and create better, more reliable outcomes.

British manufacturers are renowned for their ability to integrate cutting-edge technology to improve traditional manufacturing techniques, such as quicker development with 3D printing for casting. 3D Printed Rapid Prototyping is one of the best ways to minimise development costs on iterations of your product. It involves using our advanced thermojet wax printer to create your intended casting quickly with wax, where it can be assessed and improved before committing to tooling for casting moulds.

This, as a result, enables the production of highly sophisticated and reliable products that meet the rigorous demands of today's global market. The UK’s commitment to research and development is set to improve each year as the governments and markets see the increased reward returns from investing in our industry.

The UK's manufacturing sector is guided by strict standards of excellence that guarantee quality and safety. Organisations such as the British Standards Institution (BSI), the Cast Metals Federation (CMF) and more support businesses to maintain these standards, ensuring that British-manufactured products consistently meet or exceed global expectations.

We employ meticulous attention to detail during every stage of the casting process, from the rapid casting prototyping design and tooling to the control of the metal's compositional flow and the conditions under which it is poured and cooled. Quality control measures, such as sparking and dimensional inspections, are crucial to identify and rectify any defects before the castings proceed to subsequent manufacturing stages. For example, we guarantee that our work and the suppliers we work with are, at a minimum, ISO9001-2015 certified.

Manchester-Based Metal Casting Foundry: Dean Group International

With over 50 years of experience in the metal casting industry, our Manchester-based foundry employs the latest manufacturing techniques and technologies to deliver exceptional results. Our commitment to quality is evident in our certifications, including our membership in the Cast Metals Federation.

With Dean Group as your partner, you can trust that you're working with a reliable, cost-effective, and highly competitive metal casting company that is thriving. Contact us to discover how we’ll improve your next project.