Overview | Processes | Technologies | Sectors | Other Services | Contact
Would you like to discuss a project?
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
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
Fast turnaround
Prototype & production quantities
No tooling required
Geometric freedom
Can be combined with conventional moulding processes
Specification
Highly compatible: Furan binder system
Large bed size: 1,800 x 1,000 x 700mm,
Fine layer thickness: 280 - 500μm
Fast build speed: 60,000 - 85,000 cm3/h
High tolerance: CT9 achievable
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
Often 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
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.
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
FINISHING
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?
