Precision: Industrial Casting Solutions for High-Performance Commercial Vehicles

At Grainger & Worrall, we deliver high-integrity aluminium casting solutions that meet the demanding requirements of the modern commercial vehicle sector.

Advanced Aluminium Casting for the Commercial Vehicle Sector

Our expertise in gravity and low-pressure precision sand casting solutions allows us to produce lightweight yet durable components that enhance vehicle performance, efficiency and reliability. From powertrain and chassis structures to thermal management and e-mobility solutions, our industrial casting expertise ensures components excel under the toughest operating conditions.

With over 70 years of foundry innovation, Grainger & Worrall delivers complex, high-performance aluminium casting solutions for trucks, off-highway and heavy-duty applications across the commercial vehicle sector. Our high-integrity commercial vehicle castings optimise efficiency by reducing mass while maintaining the structural strength demanded in these challenging environments.

Key advantages of our commercial vehicle castings:

Strength-to-Weight Ratio: Our aluminium castings offer good mechanical properties, while reducing overall vehicle weight for improved fuel efficiency across key vehicle parts such as electric/hybrid/ICE powertrain components, transmission housings, and structural gigacastings.
High-Performance Thermal Conductivity: Critical for electric vehicles and hybrid applications, including EV battery housings, cooling systems and advanced powertrains, our castings enable effective heat dissipation and extended component lifespan.
Complex Geometries, Reduced Machining: Our precision casting solutions enable intricate component designs, reducing post-processing and streamlining manufacturing.

Why Grainger & Worrall for Commercial Vehicle Castings?

We understand the pivotal role of weight reduction, material integrity and efficiency in the commercial vehicle sector. Our state-of-the-art facilities, dedicated R&D teams and bespoke alloy compositions enable us to lead the way in industrial casting innovation, supporting the automotive industry’s shift towards electric vehicles and reduced environmental impact.

Rapid Prototyping & Giga Casting Facility: From single prototypes to large-scale gigacastings, we accelerate development cycles using advanced simulation, digital twin technology and large-format sand printing, ensuring faster iterations and reduced lead times.
Quantity Flexibility – 1-off to 10,000-off: Whether you require a one-off prototype or scalable production runs, our commercial vehicle castings are tailored to your quantity needs, delivering consistent quality across every batch.
End-to-End Engineering Support: Our in-house design, simulation and metallurgical expertise ensure each component, from electric drive units to engine blocks, is optimised for performance, manufacturability and durability.

Innovation meets Quality

Grainger and Worrall are passionate about innovation and quality. It impacts everything we do. Whether it's innovating with rapid prototyping, or driving lightweighting for lighter, more durable F1 engines, we make sure each and every part is fit-for-purpose and meets the quality specifications our customers expect. But don't just take our word for it, check out our accreditations below.

SO, WHAT ARE YOU WAITING FOR...

Want to get a clearer understanding of the sand casting process?

Download our FREE ebook on "The basics of the sand casting process" and get an overview of how battery trays, EDU housings, and other complex shapes can be cast in Aluminium or Ferrous alloys.

GW_Sand Casting Process Map v2T