RAPIDCAST - PROTOTYPE CASTING

Home / Divisions / Newby Foundries RapidCast

Newby Logo Rapidcast 05
Newby Rapidcast Img

Would you like to discuss a project?

Specialists in the development & production of rapid prototype sand castings

Newby Foundries RapidCast manufacture and supply rapid prototype castings in a variety of sizes, materials, finishes and quantities. We utilise the facilities of the Newby Foundries Group, along with our own range of 3D printing processes, to provide customers with the most suitable casting solution for many applications. Depending on customer requirements our prototype castings are highly representative of, or identical to production parts.

  • 1,260 Litre 3D Sand Printer
  • 7 Laser 3D Scanner
  • SolidWorks CAD Software
  • MagmaSoft Casting Simulation Software

Newby RapidCast provides a rapid prototype casting service for:

  • 1 offs
  • Limited runs
  • Development from prototype to production
  • NPI (New Product Introduction)

Primarily we produce castings in conjunction with the Newby Foundries Group:

Collab Group 01

Collaboration is Key

We work with the Newby Foundries Group to provide a comprehensive service.

Rapid Time 01

Rapid Lead Times

Several 3D printing options are available for super-fast turnarounds.

Volumn 01

Fully Representative Prototypes

We produce prototypes which are identical to production castings.

PROCESSES

For other non-ferrous sand castings we can provide select partner foundries with prototype moulds or tooling and supply customers with prototype castings in materials that would not otherwise be achievable. For lost wax prototypes please visit Newby Foundries Investment Casting. We also work with select sub-contact suppliers for services. Various finishing options are available and if needed castings can be supplied fully machined.

Find out more about the processes we offer below.

Iron Sand Printer

3D Sand
Printing

  • Furan system
  • Specification
    • Highly compatible: Furan binder system
    • Large bed size: 1,800 x 1,000 x 700mm,
    • Fine layer thickness: 0.28mm
    • Fast build speed: 60,000 - 85,000 cm3/h
    • High tolerance: CT9 achievable
  • Fast turnaround
  • Prototype and production quantities
  • No tooling required
  • Geometric freedom
  • Can be combined with conventional moulding processes
3d Printed Tooling

3D Printed Tooling / Airset Moulding

  • Markforged X7
  • Carbon fibre filled nylon
  • Continuous fibre reinforcement
  • Short lead times
  • Low volume batches
  • Basic non-cored castings
  • Other uses
    • Functional prototypes
    • Fixtures
    • Lost wax tooling
  • Specification
    • Large bed size: 330 x 270 x 200mm
    • Fine layer thickness: 50 - 200μm
Airset+moulding

Resin Tooling / Airset & Cold-Box Moulding

  • Low density grade 750 resin board
    • Reduced lead time
    • Lower cost
Iron Shell Moulding

Production Tooling

  • All casting processes from the Newby Foundries Group are available for prototypes
Hybrid Moulding

Hybrid Moulding

  • Each mould and core process has its own
    unique blend of the following properties
    •  Cost
    • Lead time
    • Durability
    • Strength
    • Thermal resistance
    • Rigidity
    • Surface finish
    • Tolerance
  • Therefore the optimal casting solution is a combination of processes

Technologies

As standard we offer in-house design for manufacture services using cutting edge software such as SolidWorks for CAD and MagmaSoft for mould flow analysis & solidification simulation. Other technology services include 3D laser scanning for casting & tooling validation and reverse engineering.

3d Scan

3D Laser
Scanner

  • Reverse engineering
  • Casting validation
  • Tooling Validation
  • GOM Suite software
    • Deviation plot colour map reports
  • Handheld system
    • Easy to use and portable
  • Fast operation
    • 30 blue laser system
    • Scanning rate: 2,020,000 measurements
  • High accuracy with variable resolution
    • Volumetric accuracy: 0.02mm
  • Suitable for large components
    • Scanning area: 410 x 400mm
    • Integrated photogrammetry for larger parts
  • Deep hole capture
Iron Design

MagmaSoft Casting Optimisation Software

  • Mould flow analysis
    • Flow rate
    • Filling temperature
  • Solidification simulation
    • Hot spot prediction
    • Porosity prediction
    • Casting yield
    • Core gas prediction
  • Virtual optimisation of casting processes
Solid Works

SolidWorks

  • CAD engineering software
  • Design for manufacture
  • Thickness analysis
  • Draft analysis

Sectors

NEWBY FOUNDRIES RAPIDCAST OPERATE IN THE FOLLOWING INDUSTRIES:

Our broad customer base spans many sectors and industries including automotive, electric vehicle, defence, oil & gas, rail, construction and general engineering OEMs. Examples of castings we produce include turbine housings, bearing housings, battery enclosures, brackets, hydraulic valves, manifolds, housings.

Automotive

EV

Defence

PUMP

Hydraulic

Oil & Gas

Rail

Engineering

OTHER SERVICES

Discover the services Newby Foundries RapidCast can also assist with:

Iron Gallery Quality

QUALITY

  • Material testing laboratory
  • Dimensional analysis reports
  • MPI, DPI & X-ray
  • Pressure testing
  • Ultrasonic testing
Steel Finishing

FINISHING

  • Machining
  • Heat treatment
  • Pickling & passivating
  • Plating
  • Painting
  • Anodising
  • 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.

We produce rapid prototype castings using the latest technologies such as 3D sand printing, simulation software and 3D scanning

Would you like to discuss a project?

contact Newby Foundries rapidcast

Newby Foundries are specialists in the development & production of rapid prototype sand castings.

Contact us to arrange a consultation or to chat to one of our team members today.





    Any information you submit here will only be used by Newby Foundries RapidCast to contact you directly and will not be shared with third parties. Please also read our Privacy Policy notice.

    Telephone: +44 (0) 121 556 4451
    Email: sales@newbyfoundries.co.uk

    Head Office:
    Newby Foundries Ltd
    Smith Rd, Wednesbury, West Midlands, WS10 0PB, United Kingdom