Specialists in the production of high quality shell & airset castings in various grades of iron
Our large purpose-built facility in the West Midlands primarily produces complex, high tolerance shell and airset castings for a variety of industries in various grades of iron.
16,000m² Facility
10,000kg of Iron Cast Daily (Single Shift)
5 Induction Furnaces
4 Two Station Shell Moulding Machines
Would you like to discuss a project?
Telephone: +44 (0) 121 556 4451
Email: sales@newbyfoundries.co.uk
100kg High Tolerance Castings
Facilitated by our unique vacuum backed shell moulding process to CT9 tolerance.
High or Low Volume Runs
From tens to tens of thousands, we have the flexibility to cater for both.
IATF & ISO Quality Management
Accredited to both IATF 16949 & ISO 9001 for the shell & airset processes.
Processes
Primarily our iron foundry produces castings using the airset, shell moulding and unique vacuum-backed shell moulding processes but we also have greensand capabilities and an in-house 3D sand printer. Therefore, we can provide customers with the most suitable casting solution for many applications. Our range of processes also enables us to produce cost-effective casting iron in various quantities from tens to tens of thousands.
Find out more about the processes we offer below.
Shell & vacuum backed shell moulding
Medium to high volume
Plate size 600x400mm
Up to 100kg
CT9 tolerance
IATF 16949
Fine surface finish
High strength cores
Airset moulding
Low to medium volume
Up to 250kg
CT10 tolerance
Cold box core blowing
Low to high volume
CT9 tolerance
Low cost tooling
Greensand moulding
Low or batch volume
Up to 20kg
CT12 tolerance
3D Sand Printing
Furan system
1,800 x 1,000 x 700mm bed size
Layer thickness: 280 - 500μm
No tooling required
Undercuts possible
CT10 tolerance
Materials
We manufacture iron castings in a range of grades including grey, ductile, and vermicular irons, and alloy irons such as NiResist and SiMo. Customer specific grades are also available on request. Our 5 induction furnaces allow us to change grades within minutes and cast parts weighing from as little as 200g up to 250kg.
We can produce all grades of the following materials. Non-standard and customer specific grades are available on request.
Grey irons
High compression strength & dampening qualities.
Ductile irons
(spheroidal graphite, SG, or nodular) Ductile with a high tensile strength.
Vermicular graphite irons
Characteristics in-between grey and ductile irons.
Austempered ductile irons (ADI)
Heat treated for increased strength & wear resistance.
SiMo (Silicon Molybdenum) irons
Resists oxidisation at high temperatures.
NiResist irons
Resistant to corrosion at high temperature.
Newby Foundries are committed to sourcing materials from companies that share our values in relation to human rights, ethics and environmental responsibility. We demand our suppliers comply with our code of conduct, and meet our sustainability expectations, including conflict free sourcing of materials. To ensure this commitment is fulfilled Newby Foundries ensures that its products are produced using only materials which can be proven to have originated from non conflict sources.
Sectors
Newby Casting iron foundries operate in the following industries:
We produce castings iron for a wide variety of OEMs in sectors such as automotive, hydraulic and pump components such as turbine housings, bearing housings, compressor covers, valve spools and pump bodies construction, pumps and hydraulics. We also make various general engineering castings.
Equipment
Design
5x SolidWorks CAD software licences
MagmaSoft casting simulation software
Core making
9x shell core blowing machines
Cold box core blowing machine
CNC core drilling robot
Melting
4x 550kg induction furnaces
1x 350kg induction furnace
16 element spectrograph
Moulding
1,800 x 1,000 x 700mm furan 3D sand printer
4 x 2 station polygram shell moulding machines
10 ton per hour airset mixer
Sand reclamation
Thermal sand reclamation plant
£1.2m investment in 2012
Self sufficient for coated shell sand
Sand laboratory facilities
Blasting
3x tumble blast machines
Table blast machine
Nozzle blast machine
Fettling
4x CNC fettling robot
Large CNC fettling robot
Measuring
3 axis coordinate measurement machine
7 laser 3D scanner
Other Services
Discover the services Newby Foundries Iron can also assist with:
Quality
Material testing laboratory
Dimensional analysis reports
PPAP & APQP
MPI, DPI & X-ray
Pressure testing
Ultrasonic testing
Finishing
Heat treatment
Pickling & passivating
Plating
Painting
Galvanising
Divisions
Explore the Newby Foundries Group
The Newby Foundries Group produce high quality castings in a variety of materials, sizes & finishes across our 4 sites. Our range of casting processes, combined with our ability to develop castings from prototype through to production means we can provide customers with an optimal casting solution for many applications.
Our market leading iron foundry produces quality castings with low lead times at competitive prices
Would you like to discuss a project?
contact Newby Foundries Iron
Newby Foundries are specialists in the production of high quality shell & airset castings in various grades of iron.
Contact us to arrange a consultation or to chat to one of our team members today.
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Telephone: +44 (0) 121 556 4451
Email: sales@newbyfoundries.co.uk
Address:
Newby Foundries Ltd, Smith Rd, Wednesbury, West Midlands WS10 0PB
