Once the sand and ceramic halves are mated together, the filler heads are fitted and the calculated amount of aluminium is poured into the mould in one continuous operation.

Although this aspect of the manufacturing process is only a part of the overall system we consider it to be of prime importance to ensure consistent high quality castings. We therefore use a special aluminium alloy that is tailored specifically to the requirements of a rotational mould. We only use ‘virgin’ aluminium ingots and we do not re-melt any excess material.

Each batch of aluminium that is being prepared for casting is carefully screened and every melt has to pass a computer controlled check on important properties such as density, grain-size, viscosity, before it is passed fit for pouring. In order to avoid climatic variations the foundry is completely humidity controlled thus ensuring a stable production environment.

Once the melt has been poured into the moulds and the aluminium has cooled down to a certain temperature it can then be moved to the break-out chamber. Here to release the castings, the sand and ceramic halves are broken away. The aluminium shells are prepared by cutting off the runner systems, risers, etc. before they are passed on to the finishing department.