A Telford-based automotive specialist, who has seen domestic and global sales rise significantly, has been named as the ‘Best of British Casting Company’ at the recent UK Cast Metals Industry Awards.
Magna Cosma Casting UK has defied uncertainty in the sector to post one of the best years in its history, impressing judges with the way it has developed a high-pressure die casting digital twin whilst also leveraging design methodology and traditional manufacturing methods.
This approach has seen it boost the workforce by 40% and has been critical in helping it support the production of large structural body and chassis castings that reduce costs and increase value for UK and international customers.
Organised by the Cast Metals Federation (CMF), there were also major accolades for Kent’s Maybrey Precision Castings and the Black Country’s Newby Foundries (joint Component of the Year winners), with Goodwin Steel Castings claiming the Innovation title.
The Stoke-on-Trent-based company, a provider of critical duty steel castings for the petrochemical, power generation, nuclear and defence sectors, has implemented a remarkable carbon neutrality plan that has resulted in several firsts for the foundry industry.
A host of shopfloor innovations has seen it reduce its CO2 from 17 to 7 tonnes per tonne of product and this has reduced its Carbon Border Adjustment Mechanism (CBAM) liability by nearly 60%.
Having obtained the ISO50001 accredited energy management system, Goodwin Steel Castings has also installed on-site solar generation which, with an output of 3.5MW, has generated 8.4% of its total electricity usage over the last twelve months. It is now aiming for carbon neutrality by 2035.
“The UK cast metals sector continues to push boundaries, to innovate and to embrace technologies like 3D printing, simulation and digital twins…this is clearly evident with the depth of quality we saw across our 20 finalists and our eventual four winners,” explained Dr Pam Murrell, Chief Executive of the Cast Metals Federation.
“We can be proud of what we make, and the way that we make our castings, largely using recycled metal. There is no doubt in my mind that our industry can be part of the Government’s solution and Industrial Strategy to grow UK manufacturing, our supply chains and the wider economy.”
The UK Cast Metals Industry Awards, which attracted 180 guests at the Drayton Manor Resort in Tamworth, focused on the great castings being manufactured in metal by UK foundries, and their huge achievements in innovation, growth, and component performance.
Co-presented by Dr Pam Murrell and comedian Ian Stone, the evening clearly showcased the successes of the sector, the major strides it is making in supporting a more sustainable manufacturing world and its increasingly global reach.
This was typified by one of the joint component winners, with Maybrey Precision Castings producing a series of 52 unique castings in silicon bronze that was used to create a series of statuesque heads that are now on display in the memorial sculpture park in Alabama.
The foundry carried out significant design work to divide the concept into castable sections, taking into account the dimpled fishing required and the numerous undercuts around the eyes, ears and noses – as specified by Digital Sculptor, Rayven Shaleigha D’Clark, in her pioneering commission by the Equal Justice Initiative ‘Black Renaissance’ project.
With both investment and sand casting unviable, printed sand moulds were employed with the team creating a double pour running system to ensure minimum turbulence and quiescent filling.
Highlighting the diversity of the casting sector was the other joint component winner Newby Foundries.
The Wednesbury-based company has created a motor housing in aluminium for the next generation of electric vehicle, developing a product that improves the cooling performance whilst reducing the number of parts from two to one.
Judges also believed that the 3D printing and sand casting techniques used could inform a new way of doings for the industry.
Pam concluded: “Celebrating the ‘Best of British Casting’ is always a timely reminder of the impact our sector has on the rest of the world. We’re often at the heart of some of the globe’s most critical products and our desire to embrace the circular economy will ensure we remain a critical partner going forward.
“A massive thank you to our main sponsor LG Energy and all our other sponsors. Without your backing this event wouldn’t be possible.”
