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We are the global leaders in complex metal shape casting technology.
As one of the world’s most experienced independent sand casting and machining firms, we’ve built our reputation on a deep understanding of metallurgy, chemistry, fluid dynamics, and the complex stresses and strains that define excellent casting. This expertise underpins our ability to produce highly complex aluminium sand castings with precision and reliability.
Our commitment to innovation drives us to continually improve the casting process for the future. As the demand for lighter, stronger, and more efficient castings grows, we push the boundaries of science and engineering to deliver solutions that are not only high-quality but also timely and sustainable.
For projects demanding reliability and versatility, our gravity casting delivers robust, precision components with impressive consistency.
Perfect for complex parts in low to medium volumes, this process is not only cost-effective but also ensures excellent dimensional accuracy and surface finish. From automotive to industrial applications, Grainger & Worrall’s gravity castings set the standard for quality and dependability.
When your application demands absolute integrity, our low-pressure casting process is the answer. Using controlled pressure techniques and our in-house developed rollover process, we produce high-performance components trusted by the world’s top motorsport and high-end automotive manufacturers.
Expect exceptional precision and integrity, developed to withstand the most demanding applications.
Experience the best of both worlds with our series foundries. Utilising the precision sand cast process, we offer flexibility while also optimising economies of scale for limited and pre-production tier 1 automotive supply. From engine cylinder blocks to ancillaries, we provide top-quality castings to meet all your needs.
Step into the future of automotive manufacturing with Grainger & Worrall’s Gigacasting. Our revolutionary Gigacasting process enables the prototyping of large, complex, single-piece aluminium structures.
Ideal for automotive chassis and architectural applications, our Gigacasting prototypes empower world-leading OEMs to develop more efficient solutions, turning bold concepts into reality.
We specialise in highly complex, gravity-fed air set sand castings. This process is cost-effective, agile, and produces strong mechanical properties. By using multiple sand mediums such as silica, chromite, alumina and zircon, combined with coatings and chill placement, we achieve consistently high casting integrity.
Advances in vehicle and engine design demand lighter, more powerful solutions. Our gravity aluminium castings deliver on these needs, making them ideal for low-carbon vehicle technologies and future mobility platforms.
Yes. Our series foundries combine precision sand casting flexibility with economies of scale for pre-production and Tier 1 supply.
We typically produce engine blocks, cylinder heads and EV castings, with annual volumes between 1,000–10,000 units and capacity for up to 90,000 castings.
Absolutely. Beyond casting, we offer engineering, machining, validation, sub-assembly and final assembly, delivering fully validated components ready for engine or vehicle build.
Gigacasting improves structural integrity, reduces weight and cost, and streamlines assembly. Using advanced sand casting and 3D-printed cores, we offer rapid design changes, faster lead times and reduced tooling costs, all while reclaiming sand to support sustainability.
With decades of championship-winning engine and transmission programs, we offer unparalleled expertise. Using CT scanning, casting simulation and the Cosworth Rollover Casting process, we deliver high-integrity, lightweight castings for the world’s most demanding motorsport applications.
We follow the golden rules of casting: minimising defects from melting, controlling oxide formation, avoiding gas porosity, and ensuring correct temperature gradients and feeding. These practices, refined over the years, underpin our reputation for producing globally renowned, reliable castings.
We are the world’s leading experts in sand casting, trusted globally for producing the highest-quality aluminium castings.
Whether for motorsport, automotive, aerospace or industrial markets, we deliver the “Grainger & Worrall difference”: expertise, innovation and reliability.
