Whether you’re looking for your first die casting partner, a replacement for your incumbent supplier or simply a second option to increase choice, we have the capability to support your needs and add value at every stage.Many of our customers come to us with similar questions. Here’s a few that could help you…
Can I Get A Complete Die Casting Solution?
When you’re designing a new part for a product, a whole toolkit of skills and specialist equipment is required to bring an idea to reality.
There aren’t many suppliers who can offer a complete solution, from design to manufacture. This means that many OEMs risk leaning on several suppliers for a single project - with a likelihood of added expense, production delays and a lack of overall cohesion, resulting in a final product that doesn’t match your specification.
MRT Castings is different. We provide an end-to-end solution which takes you from idea to product, including:
- Design for manufacture
- High pressure die casting
- Gravity die casting
- CNC machining
- Surface finishing
- Mechanical assembly
… and more.
We also have long-established relationships with expert sub-contractors who we trust with projects such as toolmaking or specialist finishing. Where a sub-contractor is required, we always continue to manage the project as if it were taking place in-house, ensuring a seamless process from design to delivery.
How Do I Develop A New Die Cast Component From An Initial Concept?
MRT's technical team have been designing quality castings for 75 years. We have the knowledge and experience to know what will work for your component and can help your project to achieve success.
Die cast components require specific features such as draft taper and even wall thicknesses, as well as the avoidance of undercuts and isolated heavy sections. We can examine your concept to ensure it’s prepared for manufacture, without the risk of costly mistakes later down the line.
When you consult us early in the design process, we can enhance the efficiency of your project at every stage - including machining, surface finishing and assembly. Just get in touch and our experts will let you know how we can help.
Which Die Casting Process Is Best Suited To My Component?
If you’re not sure which casting process is best for your project, we can help.
Our state-of-the-art facilities offer a full range of casting processes and we’re always on-hand to provide you with advice and guidance based on years of industry experience. So, there’s no need to take a risk on your die casting process – we’ll let you know the best route to take based on the needs of your component.
As an overview:
- High pressure die casting provides the shortest route from molten metal to completed component. Molten metal – often aluminium - is injected into a hardened tool steel mould and allowed to solidify under pressure before ejection.
- Gravity die casting uses cast iron moulds to produce components more accurately and cheaply than some other methods, such as sand casting. Rapid chilling gives excellent mechanical properties, whilst non-turbulent filling ensures production of heat-treatable gravity castings, with minimal porosity.
Can I Get A Prototype Of An Aluminium Die Casting?
We understand the issues involved with committing to production tooling and for this reason we offer a full range of prototyping options.
From simple nylon 3D prints, right through to sand cast or machined from solid full-function samples, your prototype can quickly be made ready for testing.
This diligence gives businesses the information they need to progress with a project – confident in the knowledge that the components are all fit for purpose and that investment will see a fully functional, market-ready product.
Should I Re-Shore Die Casting Production To The UK?
It was once common to move volume production overseas to benefit from their lower labour costs. However, the tide is turning.
Transport costs have increased, as has the pressure for reduced lead times – making overseas production far less appealing to manufacturers who prioritise efficiency.
Increased use of automation, the latest technology, world-class manufacturing and other productivity gains have helped us to reduce the differentials between the UK and lower-labour cost competitors. We’re sure that if you speak to us, we’ll find the efficiencies you need to prioritise both quality and long-term value.
Can I Use Existing Tooling For A New Die Casting?
Don’t stay with a poor supplier because adapting existing tools seems too stressful. We can supply you with your ongoing requirements while also allowing you to benefit from all that our expertise has to offer.
We'll give you an honest assessment of what’s required to adapt the tools to fit our processes and aim to get you back into production as quickly and economically as possible.
Can I Convert A Machined Solid Part To A Die Casting?
Machining an intricate shape from solid billet means a lot of material wastage, as well as a lot of cutting time.
CNC machining can be an efficient production method for one-offs and very small batches, but once you get into volume production, die casting can quickly deliver significant savings – both in cost and lead time.
Casting is a near-net-shape manufacturing process, meaning minimal wasted material – as well as minimal secondary operation machining. So, converting a machined solid part to a die casting often makes a lot of sense; but if you still aren’t sure, please get in touch with us and our experts will be happy to advise.
What Are The Quality Requirements For High Pressure Die Casting In The UK?
At MRT, we have zero tolerance for items which aren’t manufactured to the required spec. Not every foundry will have the same commitment to quality, so it’s important to do your research and ensure your goals are aligned with that of any potential partner.
Our quality management system is accredited to ISO9001:2015, so you can have the confidence that we are independently audited and consistently performing to a high standard. In addition, we invest heavily in workforce training and development, as well as our inspection software, to guarantee the accuracy of every component we produce.
Ready to discuss a casting idea?
MRT Castings are experts with over 75 years’ experience in the manufacture of high-quality aluminium and zinc die castings, across a wide range of applications and industries.
Simply get in touch today and we’ll be happy to assist with your next project.