Alucast: Investment in new CNC machining shop, paying off by securing contracts in electrification sector

Alucast’s fresh £2.5 million investment in its new CNC machining shop is paying off, as the new technology is playing a vital role by supporting the firm to secure new contracts in the electrification sector.

The UK’s leading independent aluminium foundry is using its up-scaled five-axis capability and Magmasoft casting simulation to develop and produce a line-up of complex casings and housings for high profile car makers across Europe.

Some of these products are liquid-cooled and feature complex core designs, requiring high integrity castings that must be leak-proof and finished with the latest machining techniques.

During the early days, the management team at the Wednesbury manufacturer is expecting volumes destined for electric powertrain/vehicles to account for 25% of its turnover going forward and this is one of the reasons it has decided to join a new UK cluster featuring Balluff, Brandauer, C-MAC SMT and PP Control & Automation.

Alucast as a group collectively employs over 400 people and boasts sales in 35 countries and will offer a single-source supply chain solution for electric motors, drivetrain components, battery cells, casings and housings, transfer laminations, PCB assemblies and wider infrastructure services.

Tony Sartorius, Chairman, Alucast explained: “Our engineers have been working with the car makers and tier 1s on a range of new development parts that can be used in electrification.”

“Casting is a great way of giving component strength, whilst helping to reduce weight by using aluminium. We also have all the technologies you need in-house, including the four main casting processes, prototyping, finishing, five-axis CNC and design input through industry-leading software.”

He continued: “Over £1 million of orders have already been secured in this field and we believe we can at least treble this through our involvement with the electrification cluster that has been born out of the Manufacturing Assembly Network.

“It gives us expertise across a range of ‘in-demand’ manufacturing disciplines and the capacity to take on significant projects, not only in automotive but in other sectors where electric power could be key.”

MAN’s ‘Electrification Cluster’ was launched in August with a major digital marketing campaign and dedicated E-brochure that details the group’s capabilities and supply offering.

Richard Halton, Business Development Manager at C-MAC SMT, a leading independent provider of complex, high-reliability electronics and system assemblies, said: “We are delighted to welcome Alucast to the cluster and are already working with it on several exciting new development projects where its knowledge of housings and casings is coming to the fore.”

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