Sand Casting
Maybrey operates one of the most versatile sand casting facilities in the UK. Our sand foundry produces complex castings in a wide range of ferrous and non-ferrous materials, from a single piece for a heritage restoration to batch production for aerospace and commercial customers.
Materials
We cast in the following materials. Specific grades and alloys are available on request and will be confirmed at the quotation stage.
Grey Irons
General engineering, architectural, and heritage castings. Excellent machinability and damping characteristics.
Ductile Irons / SG Irons
Higher tensile strength and impact resistance than grey iron. Suitable for load-bearing and structural applications.
Aluminium Alloys
Lightweight, corrosion-resistant castings for aerospace, commercial, and architectural applications.
Copper-Based Alloys
Including silicon bronze. Corrosion resistance, aesthetic quality, and suitability for art and architectural work. LG2, LG4, AB2, Others on Request
Silicon Bronze (Copper-Based Alloy)
Prized for its warm golden colour, long-term patina, and weldability. The material of choice for monumental sculpture.
Aerospace & Defence Castings
Art Foundry Castings
Architectural & Heritage Castings
Commercial Castings
Capacity
Iron castings
UP TO 750KG
Aluminium castings
UP TO 250KG
Copper-based castings
UP TO 250KG
Volume
Low to mid volume.
Bespoke and batch production. Not a high-volume production foundry.
The Process
Sand casting uses a compacted sand mould to shape molten metal. At Maybrey, we pump dried silica sand to eight Omega sand mixers covering both our iron and aluminium sections. Each mould is made to the pattern or drawing supplied by the customer or produced in-house by our tooling team.
Once the mould is assembled and any cores set, metal is poured at the correct temperature for the alloy. After solidification and cooling, the casting is knocked out, fettled, and passed to our inspection and post-processing departments.
Quality Assurance
Our sand foundry operates under ISO 9001:2015 and, for aerospace and defence work, AS9100 Rev D. We have three spectrograph machines covering ferrous and non-ferrous requirements. All destructive tensile tests and non-destructive tests are carried out by NADCAP-approved suppliers.
We can take your casting through to finished component: machined, coated, tested, and ready to fit.
