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Telephone: +44 (0) 121 556 4451
Email: design@newbyfoundries.co.uk
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:
- Newby Foundries Iron – Iron sand cast prototypes
- Newby Foundries Steel – Steel sand cast prototypes
- Newby Foundries Light Alloys – Zinc and aluminium sand and gravity die cast prototypes
- Newby Foundries Precision Machining – Prototype machining
Collaboration is Key
We work with the Newby Foundries Group to provide a comprehensive service.
Rapid Lead Times
Several 3D printing options are available for super-fast turnarounds.
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.
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 / 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
Resin Tooling / Airset & Cold-Box Moulding
- Low density grade 750 resin board
- Reduced lead time
- Lower cost
Production Tooling
- All casting processes from the Newby Foundries Group are available for prototypes
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 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
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
SolidWorks
- CAD engineering software
- Design for manufacture
- Thickness analysis
- Draft analysis
OTHER SERVICES
Discover the services Newby Foundries RapidCast can also assist with:
QUALITY
- Material testing laboratory
- Dimensional analysis reports
- MPI, DPI & X-ray
- Pressure testing
- Ultrasonic testing
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.
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.
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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