Manufacturer looks to build on £1m of electrification wins following investment

A recent £2.5m investment in its new CNC machining shop is paying off for a Black Country manufacturer, with the new technology paying a pivotal role in helping it secure new contracts in the electrification sector.

Alucast, the UK’s leading independent aluminium foundry is using its increased 5-axis capability and Magmasoft casting simulation to develop and produce a range of complex casings and housings for car makers across Europe.

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.

The management team is expecting volumes destined for electric powertrain/vehicles to account for 25% of its turnover going forward and 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.

This group, which collectively employs over 400 people and boasts sales in 35 countries, 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.

“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,” said Tony Sartorius, chairman at Alucast.

“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 added: “Over £1m 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 (MAN).

“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.”