Automotive Casting Expertise | Grainger & Worrall

Lightweight Aluminium Castings

We create the high-integrity, lightweight aluminium automotive castings demanded by the industry for structural and ICE, EV and Alt-Fuel automotive components.

We use our sand casting expertise, as well as materials knowledge, to create bespoke aluminium alloys that are strong, light and precise, driving modern applications. And we do it accurately and fast. Every time.

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Casting for Automotive

We specialise in manufacturing high-quality aluminium automotive castings that meet exacting industry demands for complex powertrain automotive components. Our sand casting expertise, combined with our materials knowledge, enables us to produce customised aluminium alloys that are strong yet lightweight.

Our rapid and accurate production process ensures consistent quality with every casting and we can enhance it further with finishing processes, such as CNC machining for tighter tolerances and surface specifications.

We develop specific and bespoke alloys that retain their mechanical properties in temperature-critical applications, crucial for ICE engine block casting.

Our high-integrity sand castings for ICE and EV allow us to supply prototype engine components which model (HPDC/LPDC) production parts with ‘Make Like Production’ (MLP) properties.

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Scalable Quantities

We can take your project from the initial design iterations with a supply of 1-100 prototypes, through to bridge supply volumes of 100-3,000, right up to full-scale low-volume production of 3,000-40,000 p/a in our automated facility.

Accuracy Built In

We use inspection techniques such as CT scanning and GOM measurement to ensure we meet tight tolerance specifications and requirements, delivering high-integrity castings every time.

Adding Value

Our sand casting expertise adds value at every stage of development, including in prototyping, initial concepts and proof of concept.

Case Studies

Paving the Way for Gigacasting

In 2019/20, a large EV OEM came to us with a problem. Can you sand cast the whole front and rear underbody of a car, with the same properties as High Pressure Die Casting (HPDC), tight tolerances and impressive dimensional accuracy? Most (sensible) sand casting firms would have said no, but the Grainger & Worrall way is to innovate, think outside the box and find a solution.

We are now the go-to sand casting experts for prototyping Gigacastings for the automotive industry. We save Automotive OEMs huge initial investments and enable the smooth transition from multi-part B.I.W. structures to single-piece, Gigacast-body structures.

Lightweighting Through Efficiencies

G&W is working in partnership with major vehicle OEMs to develop lightweight chassis, powertrain and drivetrain components. We’ve developed a fast and reliable method for casting hollow aluminium components, at a lower cost compared to traditional hard tooling.

Lightweighting has always been integral to vehicle design, but it’s now even more essential due to the implementation of new electrification strategies – contributing to increased battery range.

Engine Block Casting Innovation

G&W worked with the ALIVE6 team, and in conjunction with Jaguar Land Rover (JLR) and Advanced Propulsion Centre (APC) to develop a casting process and supply chain to support leading-edge technology that developed a new type of cylinder block that used plasma coatings to reduce the weight and size of engines.

This required exploring elements such as the structural strength of the cylinder, as well as the porosity and adhesive properties of the alloys.

Cylinder Head for Historic Volvo Range

FAQs

Everything You Need to Know

How Does Grainger & Worrall Combine Innovation and Quality in Aluminium Casting?

We are passionate about innovation and quality. It impacts everything we do. Whether it’s innovating with rapid prototyping or driving lightweighting for lighter, more durable F1 engines, we ensure every part is fit-for-purpose and meets the quality specifications our customers expect. But don’t just take our word for it, check out our accreditations below.

How Do You Achieve Shorter Lead Times?

We’re able to reduce time-to-market for compressed lead times with innovative techniques and technologies to speed up manufacturing, such as 3D digital sand printing.

Bespoke alloys and the ability to create complex, net shapes with sand casting allow us to meet lightweighting and part count reduction demands in automotive components.

Can You Prototype Complex Powertrain and Gigacast Components?

We work with our automotive customers to solve complex problems with innovation and prototyping expertise in sand cast powertrain components, but also in Gigacasting. Automotive is seeing a shift from multi-component, multi-joint B.I.W. frames. We enable world-leading OEMs to unlock the potential of Gigacasting with our expertise and (Kings Award-winning) innovations.

How Can I Discuss the Details of My Project With You?

Most of what we do and who we work with isn’t in the public domain. If you’d like to talk specifics about your project, get in touch.