Casting a cleaner future.
From battery enclosures to EDUs, we're using our casting expertise, material knowledge and prototyping approach help solve the complex EV problems of lightweighting, part count reduction and material optimisation.
Aluminium castings allow us to create the lightweight, complex metal shapes required to reduce fuel use and emissions in electric vehicles, while still meeting performance expectations.
CREATING LIGHTWEIGHT, COMPLEX METAL SHAPES FOR Electric vehicles. QUICKLY
Creating lightweight, complex metal shapes for EV. Quickly.
- We use the flexibility of sand casting prototyping to create complex geometries in a single shape, at a relatively low cost and in a range of alloys.
- Our materials knowledge and expertise, especially in aluminium castings, allows us create Make Like Production (MLP) properties and We also develop unique alloy chemistries for lightweighting, recyclability and durability.

Creating lightweight, complex metal shapes for EV. Quickly.
- Our Magma simulation software allows us to prototype properties prior to production, reducing any unnecessary weight with overengineering.
- Our 3D sand printing capabilities allows us to deliver EV component parts with super short lead times.
- We use CT scanning to ensure we meet specifications and tolerancing requirements, delivering high-integrity castings.

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Battery Enclosure: Alloy Specification
We developed an alloy specification to meet EI% target for crash structure performance. GOM control was used to ensure dimensional conformance. Supported multiple development phases- 500 pcs total.
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Design Detailing and Tolerancing of EDU Housings
GW supported a major UK OEM with design detailing and tolerancing of complex, EDU housings with integrated cooling. This including design feasibility support, complex casting manufacture, full validation via CT & GOM scanning, detailing of machining drawings with manufacturing tolerances and in-house air-decay pressure test processes.
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Make Like Production (MLP) Vehicle Structure
GW developed a specific alloy chemistry and heat-treatment process to achieve Make Like Production (MLP) materials performance for large, body structure castings.
Innovation meets quality
Grainger and Worrall are passionate about innovation and quality. It impacts everything we do. Whether it's experimenting with material properties for an EV battery tray or validating an EDU housing we want to make sure each 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.