Processes
Tooling Manufacture
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Telephone: 0121 556 4451
Email: sales@newbyfoundries.co.uk
Specialists in Tooling Manufacture for Iron, Resin and Aluminium
- Resin, aluminium, iron and 3D printed tooling options available
- Suitable for shell moulding, airset moulding, cold box core blowing and investment casting
- Supports prototype, low-volume and production casting requirements
- CAD/CAM, reverse engineering and casting development support available
Processes applicable to Tooling Manufacture:
What is Tooling Manufacture?
Tooling manufacture is the production of the patterns, coreboxes, dies and related equipment used to create accurate, repeatable castings.
Newby Foundries provides tooling support across a wide range of casting processes, helping customers move from early design and prototype development through to reliable production manufacture. Depending on the casting route, tooling may be produced in resin, aluminium, iron or 3D printed materials, with each option selected according to the required process, batch size, lead time, surface finish, tolerance and cost.
For shell mould casting, Newby Foundries utilises durable iron tooling to support high tolerance production of iron and steel castings. This is particularly suited to medium and high-volume requirements where repeatability, strong core assemblies, improved surface finish and process consistency are important.
Resin tooling is used in conjunction with airset moulding and cold box core blowing processes to produce castings in a variety of metal types and grades. Prototype and limited batch resin tools can be produced using lower density resin board to reduce material cost and machining time, while production tooling can be manufactured from more durable resin grades to minimise wear over repeated use.
For investment casting, aluminium tooling provides a durable cavity for the production of sacrificial wax injected patterns. Aluminium tooling is suitable for short runs and higher-volume projects, can support complex shapes through inserts and slides, and helps provide a high-quality surface finish for wax pattern production.
Where speed and flexibility are required, 3D printed tooling can also be used for selected applications, including low-volume castings, functional prototypes, fixtures, simple moulds and lost wax tooling. Newby Foundries’ 3D printed tooling is produced using materials including PLA, PETG and carbon-filled nylon, with the most suitable option chosen around the needs of the project.
Whether a new or existing product, our expert team will support the development of manufacturable tooling that helps deliver consistent, high-quality castings.
Our Tool Manufacturing Process
Newby Foundries works closely with customers to produce practical, manufacturable designs before committing to tooling manufacture. This early-stage support is essential because tooling decisions can influence casting quality, production cost, dimensional accuracy, lead time and long-term repeatability.
We can work from existing components, CAD data, technical drawings or reverse engineering requirements to develop tooling for both prototype and production casting. Through the Newby Foundries Group, customers can access design for manufacture support, SolidWorks CAD, MagmaSoft mould flow and solidification simulation, 3D laser scanning for casting and tooling validation, and reverse engineering where required.
For sand casting applications, resin tooling can be CNC cut for high accuracy and durability, with tooling options available for airset moulding and cold box core blowing. Depending on the material and application, this may include compact frames with integral running systems, loose patterns, coreboxes and tooling suitable for large moulds or complex casting projects.
For shell moulded iron and steel castings, durable iron tooling is used to support repeatable production, high tolerance requirements and improved surface finish. Newby Foundries’ iron casting facility supports shell moulding, vacuum-backed shell moulding, airset moulding, greensand and 3D sand printing, allowing the team to advise on the most suitable tooling and casting route for each project.
For investment casting, aluminium tooling can be designed for automatic or manual wax injection machines. Tooling can incorporate inserts, slides, logos, part IDs, labels and retracting sections, with modification and refurbishment options available where required. When aluminium tooling is not appropriate for batch size or cost, resin or silicone tooling may also be considered.
Where tooling-free or accelerated routes are more suitable, Newby Foundries can also advise on 3D sand printing, 3D printed tooling and printed wax pattern options. This allows the team to support projects where rapid lead times, prototype development or low-volume production are key priorities.
Prototype to Production
Working with Newby Foundries
Established since 1890, Newby Foundries provides an industry-leading service for casting development, tooling manufacture and production casting solutions. The group produces high-quality castings across a range of materials, sizes and finishes, with four West Midlands sites and a broad range of processes available to support projects from prototype through to production.
Offering multiple casting materials and processes across the group allows Newby Foundries to provide impartial advice on the most efficient and effective tooling route for your project. This may include durable iron tooling for shell moulding, resin tooling for airset and cold box processes, aluminium tooling for investment casting, 3D printed tooling for selected rapid prototype applications, or a hybrid approach where two or more methods are required.
Our wider manufacturing capabilities also support the complete casting route, including moulding, core making, casting, machining, finishing, coating, inspection and delivery. Newby Foundries’ precision machining facility includes CNC machining centres, CNC lathes and CAD/CAM software to support the seamless manufacture of prototype and production castings.
We work across many industries, including automotive, EV, hydraulic, pump, marine, oil and gas, rail, defence, construction and general engineering, supporting customers from design and prototyping through to production and finishing.
