Alucast joins MAN cluster to build on £1m of electrification

Member News

MIM member Alucast joins fellow member Brandauer in a cluster of businesses to gain contracts in the electrification sector. This is thanks to their recent £2.5m investment in their new CNC machining workshop. 

Alucast offers gravity, high pressure, low pressure and sand casting and, due to its new machining shop, access to 20 CNC machines providing bed sizes ranging from 400mm to 630mm.

The UK’s leading independent aluminium foundry, based in the West Midlands, is using its increased 5-axis capability and Magmasoft® casting simulation to develop and produce a range of complex castings and housings for high profile car makers across Europe. 

The management team at the manufacturer is expecting volumes destined for electric powertrain/vehicles to account for 25% of its turnover going forward. This is one of the reasons why it has decided to join a new UK cluster featuring Balluff, Brandauer, C-MAC SMT and PP Control & Automation.

The Manufacturing Assembly Network (MAN) employs over 400 people and boasts sales in 35 countries and will offer a single-source supply chain solution for electric motors, drivetrain components, battery cells, casings and housings, transfer laminations, PCB assemblies and wider infrastructure services.

Some of these products are liquid-cooled and feature complex core designs, requiring high integrity castings that must be leak-proof and finished with the latest machining techniques. 

Tony Sartorius, Chairman at Alucast said: “Our engineers have been working with the car makers and tier 1s on a range of new development parts that can be used in electrification.”

“Casting is a great way of giving a component strength, whilst helping to reduce weight by using aluminium. We also have all the technologies you need in-house, including the four main casting processes, prototyping, finishing, 5-axis CNC and design input through industry-leading software.”

He continued: “Over £1million of orders have already been secured in this field and we believe we can at least treble this through our involvement with the electrification cluster that has been born out of the Manufacturing Assembly Network."

“It gives us expertise across a range of ‘in-demand’ manufacturing disciplines and the capacity to take on significant projects, not only in automotive but in other sectors where electric power could be key.”

MAN’s ‘Electrification Cluster’ was launched in August with a major digital marketing campaign and dedicated E-brochure that details the group’s capabilities and supply offering. 

This is being reinforced by a number of educational videos and potential seminars where they will aim to unpick some of the common challenges facing companies involved in this industry. 

Richard Halton, Business Development Manager at C-MAC SMT added: “We are delighted to welcome Alucast to the cluster and are already working with it on a number of exciting new development projects where its knowledge of housings and casings is coming to the fore.”

“It’s a natural fit to have a world leader in castings joining global specialists in strategic manufacturing outsourcing, sensors, inspection systems, wiring looms, high volume pressings and laminations and electronic assembly.”

Alucast’s single-source approach has seen it work with some of the world’s leading tier 1 supplier and carmakers, as well as specialists in vacuum products, hydraulics, rail, bus and commercial heating systems.

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