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...
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...
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.
How cores extend the flexibility of sand casting
Creating cores is an art in itself and follows many of the principles that dictate the production of sand moulds. Without cores, the use of sand casting would be far more limited. In addition to the ability to introduce more complex designs, internal voids and structures, cores can deliver other benefits. Even where internal voids are not needed...
Elements of a Sand Casting Running System
The gating system includes all those elements which connect the pouring ladle to the mould. The various elements include: Pouring Basin or cup, Sprue, Sprue Base Well, Runner, Runner Extension, In-gate and Riser. An effective gating system should: Fill the mould cavity completely before the metal starts to solidify Control the speed that metal enters...
The case for Sand Casting
The Sand Casting process has been a key element in manufacturing for thousands of years and still accounts for approximately 70% of all castings. Whether Sand Casting is the best option for the production of a particular component will be dictated by considerations such as the required geometry, performance, alloy choice, production run, tolerance within...
Sand Casting Foundry: Where tradition meets technology
Sand casting is a traditional process dating back many thousands of years, but components produced using this process are still an essential part of our lives today. In this article we outline the sand casting process as carried out in a modern sand casting foundry, where technology and tradition are combined. Although it dates back...