Casting Process Comparison: Sand Casting vs Shell Mould Casting
In this article we consider the differences and similarities between two closely related casting processes. Both use sand moulds to produce castings but the differences in the processes make them suited to quite different applications. Sand casting is one of the oldest casting processes dating back at least 5000 years. The simplicity and versatility of...
Constant refinement and improvement in motorsport
Working with motorsport manufacturers is a pleasure for our design engineers. There’s always a keen focus on engineering excellence, innovation and performance with pressure to refine the casting further each time. This bell housing for one of the UK’s leading race car manufacturers is sand cast in Aluminium casting alloy LM25TF (Heat Treated Casting to...
NovaCast adds to its sand core production facilities
Small but perfectly formed. Our new resin-sand mixing machine will improve both flexibility and efficiency at our Melksham foundry. The 1-Tonne per hour capacity may be small but it is the perfect solution for sand-core and small mould production, complementing the existing larger scale equipment on site.
NovaCast is working with Andover Norton to cast genuine Norton spare parts
One of the most rewarding aspects of our business is having the opportunity to work on iconic British engineering heritage. We have started working with Andover Norton, the exclusive source of genuine Norton motorcycle spare parts. This front wheel hub for a Norton Commando 750 is sand cast in LM25 aluminium with two cast-in elements;...
New Casting Process Data Sheets
Following the recent re-launch of our website, we have continued to add new content and I wanted to point you in the direction of our data sheets. We now have over 30 on the site covering the technical specifications of all the main alloys that we cast. We have also recently added data sheets for...
NovaCast improves Ecovadis rating once again
Despite tougher Ecovadis scoring methodology, NovaCast has further improved its sustainability rating with the world’s largest and most trusted provider of business sustainability ratings. Following on from our silver medal in 2023, we have once again been awarded a silver medal that places us in the top 15% of the 130,000 companies Ecovadis assesses worldwide....
NovaCast and Xylem planting project for Noah’s Ark
Noah’s Ark Children’s Venture is a charity providing a residential facility for disadvantaged and disabled children at Macaroni Woods near Cirencester. Their aim is to make a positive difference to the lives of children and young people who are experiencing social or educational exclusion, by reason of their youth, disability, poverty, or social and economic...
NovaCast provides a new public access defibrillator at it’s Bowerhill office
It’s a sobering thought that approximately 95% of people who suffer a sudden cardiac arrest will die before they reach hospital. This figure could be transformed into a survival rate of 70% if more locally available defibrillators were in place. At NovaCast, we have been working with London Hearts, an organisation set up to help...
Metal shrinkage in castings and why it matters
Within this article, we take a look at one of the issues within metal casting that is critical to get right but challenging to understand, even for those within the industry...
Bringing a piece of British motoring heritage back to life
In the early 1900’s, British car manufacturers were at the forefront of motor vehicle development. The Vulcan Motor company, based in Southport, England, was one such innovator that produced cars from 1902 until the late 1920s. Today, early examples of Vulcan cars are extremely rare collectors’ items. NovaCast was approached by a specialist engineering company...
NovaCast’s stockholding capability protects customers from Red Sea shipping delays
NovaCast’s customer base is a healthy mix of those ordering from our UK foundry, and those that want to take advantage of the more competitive rates and capacity of our partner foundries in the Far East and India. Clearly, for castings imported from these international locations, the current disruption in the Red Sea could have...
Job Vacancy: Quality Technician
Due to the substantial growth of the business NovaCast is looking to recruit a full-time Quality Technician who will be based at our foundry in Melksham. This is an exciting opportunity to work within a growing business that is investing in the latest foundry technologies and systems. The full job description can be found here...
The Differences Between Non-destructive and Destructive Testing of Metal Castings
In a perfect world, every casting would be free of defects and perform exactly and reliably to design specifications. The reality, however, is that casting metal is a process subject to a multitude of factors that affect the way that an alloy reacts throughout the process. The inevitable result is that defects are an inherent...
Why quantifying progress is essential for a sustainable future
During recent years there has been an ever-growing awareness of the impact that our activities have on the world we live in. Whatever your perspective on the causes of global warming, it is a matter of fact that most of us in the developed world cause harm to our environment through the products we consume,...
The Casting Design Development Process
In this article we run through a typical casting design process to highlight the importance of co-operation at an early stage between designer and foundry. A typical experience based on an iterative design process might be as follows. The role of the design engineers The product design engineer will design casting geometry based on the...
NovaCast embraces environmental transparency by disclosing through CDP
19.10.2023 NovaCast today announced that it has furthered its commitment to environmental transparency by disclosing its environmental impact through CDP, a global non-profit that runs the world’s leading environmental disclosure platform. NovaCast has disclosed through CDP since 2022, and in 2023 completed CDP’s Climate change & Water security questionnaires. With a record 23000+ companies disclosing...
A NovaCast Guide: “Casting Design Considerations for Design Engineers”
While there is no substitute for a close working relationship at an early stage between the design engineer and their chosen foundry, we hope that this guide will be of assistance to product design engineers. It will give an indication of the often-conflicting factors that the production team within the foundry will need to take...
A successful foundry is about so much more than just casting metal
As any buyer of castings will surely understand, there are hundreds of foundries around the world who could cast their component. The complexity of the geometry or the need to use a special alloy may limit that number somewhat, and demand and supply will dictate prices and lead times, but they will still have plenty...
Certified 100% Renewable Electricity
By its nature, a foundry is an energy-intensive business so the choice of energy supplier is a critical decision when considering the carbon footprint of the business moving forwards. As part of our commitment to sustainability, NovaCast has taken the opportunity to engage with an energy supplier that guarantees 100% of the electricity it supplies...
The Difference Between Gravity, Low and High Pressure Die Casting
Die casting is one of the most widely used casting processes but there are significant differences between Gravity Die Casting (GDC), Low Pressure Die Casting (LPDC), and High Pressure Die Casting (HPDC). Each are casting processes offered by NovaCast, so we are well placed to explain the differences and discuss the selection criteria. Getting metal...
The Leaders Council forum: Workforce Of The Future
On the 4th April 2023, a small group of business leaders, including Richard Phillips, MD at NovaCast, met at the Caledonian Club in London. The forum was convened by The Leaders Council to discuss how the workforce has changed over the past few years and the resultant opportunities and challenges. There was a specific emphasis...
Sustainability Matters
As part of our commitment to making our business more sustainable and doing our bit to improve the environment we all share, NovaCast has engaged with EcoVadis, the international sustainability ratings platform. We reported in February that we had improved our EcoVadis sustainability score by 61% in the past year. EcoVadis partners with hundreds of...
Choosing the right metal casting process
Selecting the right casting process for making a metal component is an important consideration at the early stages of product design. NovaCast has produced a guide that aims to highlight the considerations, and emphasise the importance of working closely with your foundry's design engineering team.
Metal shrinkage in castings and why it matters
Within this article, we take a look at one of the issues within metal casting that is critical to get right but challenging to understand, even for those within the industry...