We’re pleased to publish here a recent article we wrote for Electric & Hybrid Vehicle Technology….
We’re pleased to publish here a recent article we wrote for Electric & Hybrid Vehicle Technology….
Increased demand as Make Like Production concept accelerates vehicle development time and reduces costs
• Third CT scanner broadens company capacity and sustains Grainger & Worrall commitment to offering production-ready quality control
• Advanced sand-casting technique provides lightweight, durable castings
Bridgnorth-based automotive casting specialist, Grainger & Worrall has made a significant investment in hardware that increases its throughput capacity by 50%. A third CT scanner helps ensure that castings meet the stringent quality assurance and control demanded by the automotive industry. The company has experienced a substantial increase in demand for its castings, as vehicle manufacturers seek to accelerate development times of highly efficiency new models ahead of tightening emissions regulations globally.
Grainger & Worrall’s commitment to the Make Like Production concept, which was pioneered by the Warwick Manufacturing Group, produces castings for early-stage development parts that behave as a production component would. This enables extensive vehicle testing and validation to be completed, even though production line materials and manufacturing processes may be very different. It provides a vital cost and time advantage to vehicle manufacturers seeking to bring new models, packed with latest technologies and materials, to market quickly and efficiently.
“Casting of prototype components traditionally bared little semblance to final parts, but our Make Like Production mantra brings the prototyping process right up to date and in line with the fast-moving automotive industry’s requirements,” explains James Grainger, Grainger & Worrall director. “Now, prototype component performance characteristics can mimic those of production parts even in intensive test conditions. CT technology provides the fastest and most comprehensive opportunity for evaluation of material integrity and overall quality control. This latest investment into Grainger & Worrall’s leading-edge facilities is testament to our commitment to growing proactively in line with industry demand for our casting expertise and brings our investment in CT technology to a total of £1.2m.”
The latest CT machine is an industrial grade 450kV Yxlon compact CL. As well as increasing the company’s throughput capacity by 50%, it also provides the capability to scan larger components of up to 125kg, which can handle the largest structural components the company makes and reflects the increasing move to lightweight cast vehicle structures as well as drivetrain.
“Our customers rely on Grainger & Worrall components being robust enough to undergo intensive testing and validation, so the assurance of strict quality control is absolutely vital,” continues Grainger. “This latest scanner broadens our scope of work to include components that would have previously fallen outside our end-to-end production parameters. Increasing our capacity through the addition of a third CT scanner ensures that our components adhere to our own strict standards and provides customers with a reliable, proven source of castings even while demand for our speciality continues to intensify. Our commitment to Right First Time means we might well now have the largest industrial CT scanning capability in the UK.”
Global leader in the design and manufacture of complex castings, Grainger & Worrall (G&W), has appointed Phil Ward as its new Sales & Marketing director. The move signals a bold new direction for the award-winning business, which boasts Aston Martin, Bugatti, McLaren and Porsche among its prestigious client list.
Grainger & Worrall has launched a white paper detailing how the need for greater thermal efficiency in internal combustion engines (ICEs) is driving even greater innovation in the field of high-precision engine casting.
Complex metal specialist Grainger & Worrall (G&W) has played a vital part in the rapid development of a new generation waterjet launched by HamiltonJet Global.
At Grainger & Worrall, we’re proud to be a partner to the very best in the world of motorsport. Our high-specification cylinder head was at the heart of the Cadillac DPi-V.R driven to victory by Fernando Alonso in the recent Daytona 24-hour race, showing outstanding performance and durability in the most demanding conditions.
Working with OEMs is all about reducing time and cost, while maintaining quality, says Michael Cooper, executive manager at GWL Machining
Michael Cooper, Executive Manager – Machining at Grainger & Worrall, explains why the growth of electric vehicles is an opportunity, not a threat, to businesses willing to take advantage of emerging markets.
Matthew Snelson, head of quality systems at Grainger & Worrall, discusses the importance of our recent IATF16949 accreditation
How advances in lightweighting are enabling automotive OEMs to design ever more efficient vehicles
Complex machined castings specialist Grainger & Worrall’s commitment to industry and the engineers of the future has been recognised through a highly prestigious, international automotive sector award.
The hugely successful partnership between Grainger & Worrall and Gibson Technology continued apace this weekend, with three podiums at Le Mans. Gibson GK428 engines, cast by Grainger & Worrall, were utilised by all 20 cars on the LMP2 grid.
Rebellion Racing’s historic podium finish at Le Mans this weekend has delivered even more success for the hugely successful partnership between Gibson Technology & Grainger & Worrall.
We are pleased to confirm on Friday night Grainger & Worrall came home with the nights top award for ‘Company of the Year’, a fantastic achievement and first company to win for a second time. This award is testament to the hard work of all here at GW, congratulations and thank you to all.
Diversification into electrification and body in white is enabling the in-house machining facility at Grainger and Worrall to boost turnover.
This diversification is now contributing up to £8m to the group’s overall sales figures, Initially set up to deliver complex, low-tolerance machining support to Grainger and Worrall’s own cylinder heads and engine castings, the facility has since grown to work directly with OEM customers, delivering precision machined parts for customers all over the world.
Grainger & Worrall is exhibiting at Automechanika this week (5 -7 June), at Birmingham’s NEC.
Grainger and Worrall sends it congratulations to Will Power and Chevrolet after victory in the Indianapolis 500 this week. The win was Power’s first in the sport’s biggest race, and his 34th career IndyCar victory overall.
A global authority in castings has given a two-day seminar to engineers at complex metal specialist Grainger and Worrall, as the business continues to expand and improve its offering.
Professor John Campbell visited the Shropshire-based business to reinforce the principles of the recognised Cosworth sand casting process, which he helped to develop back in 1978. Now owned by Grainger and Worrall, the process was developed over a lifetime of work in the foundry industry to develop defect-free castings with dimensional accuracy, and high structural integrity.
During the two-day event, John Campbell presented the theory behind the Cosworth process to 40 members of the engineering department, before spending the second day discussing the key principles behind the idea, reinforcing best practice.
Keith Denholm, engineering and technology Director at Grainger and Worrall, explained that the Cosworth process is as integral to the business today as it has always been.
“As Grainger and Worrall moves into electrification, body in white, and subframes, we continue to operate to the principles set out by the Cosworth process to continually to optimise and lightweight casting materials. Although the process itself may change depending on each application, the principles it is based upon remain as relevant as they have ever been.
“We were delighted that such a recognised global authority in John Campbell was happy to visit our foundry and engage with our engineering team as we continue to grow, following his initial guidelines for castings success.”
A team of young engineers at complex metal specialist Grainger and Worrall is taking the lead on a new project expected to boost tourism to the town of Bridgnorth (Shropshire).
Budding engineers have already begun prototyping a series of 20 replica locomotive statues in the shape of ‘Catch Me Who Can’ – the world’s first fare passenger engine built in Bridgnorth back in 1808 for British inventor Richard Trevithick. Each statue will be hand-painted in a kaleidoscope of colours by local artists and placed in strategic locations around the town, to create an interactive walking trail.
The project is putting Grainger and Worrall’s apprentices under real-time engineering pressures. Not only are they being asked to design and engineer the statues based on a sketch drawing, but they also need to manufacture four a week leading up to the April 1 deadline, when they will be placed around the town. The replicas, which when cast and set on a plinth stand some 1.5m high, provide several external design challenges that the apprentices must overcome.
Ella Jones, a female apprentice at Grainger and Worrall, explained: “Throughout the design stage we have had to consider lots of requirements. The volume of replicas required in a short timeframe mean they must be practical to manufacture, which is why we are utilising a hybrid of traditional casting processes, together with more innovative 3D sand printing technology. They must also be corrosion resistant and have secure fixings, plus, be novel and quirky by design. Amidst all of these, we also need to ensure they replicate the original Catch Me Who Can in the best possible way.”
Matthew Snelson, director of systems at Grainger and Worrall, and director of the neighbouring Marches Centre of Manufacturing and Technology, which hosts the apprentices, added: “This project gives our apprentices experience of working in busy engineering conditions, utilising their skills in computer aided design, simulation, prototyping, 3D printing and sand casting. These are the skills Grainger and Worrall’s 700-strong team practise every day in response to demand from leading OEMs for complex metal solutions, and puts the apprentices in good stead for long, successful careers at the company.”
Grainger & Worrall has become one of the first UK businesses to achieve an internationally recognised automotive standard, backed by vehicle manufacturers including BMW, General Motors, FCA, Volkswagen and more.
Grainger & Worrall has announced that it has successfully achieved IATF16949 accreditation, reaching the highest standards for business systems, continual improvement, risk management and defect prevention in the supply chain.
Developed by the automotive industry specifically for suppliers, IATF16949 replaces TS16949 and outlines the requirements for an effective Quality Management System (QMS). The key to this is risk assessment, driving the organisation to learn from the many inputs it experiences, such as customer feedback, internal and external audits and improvement efforts, to provide the highest quality product and service to the customer.
Matthew Snelson, head of quality systems at Grainger & Worrall, said: “After detailed, on-site audits by Lloyds Register, we are delighted to have been awarded IATF16949 Certification and ISO9001 renewal.
“Achieving this widely recognised certification is a great reflection of the hard work and dedication of the Grainger & Worrall team, which continually pulls together to achieve significant uplifts in processes and quality systems.”
Grainger & Worrall received IATF16949 / ISO9001 certification in January 2018.
How a unique partnership between two UK motorsport titans created ‘the world’s most reliable motorsport engine’.
• Gibson / GW engines took ‘world first’ podiums at Le Mans in June 2017
• Of 25 LMP2 vehicles powered by Gibson / GW engines, 21 completed the circuit (four retirements were due to non-engine related issues)
• In total, the 4.2 litre GK428 V8 engines covered a distance of 143,440.03 kms in 719.5hrs
Rounding off a year that has seen significant machinery investment and continued major OEM partnerships, Grainger & Worrall has reaffirmed its commitment to motorsport with Director James Grainger becoming Vice Chairman of the Motorsport Industry Association (MIA).
The high precision castings expert has been an MIA member for the past decade, representing the sector on such topics as skills, Brexit, and the industry’s challenge to embrace low carbon initiatives across motorsport and passenger cars. This year, Grainger & Worrall has also played a pivotal role in launching the £4 million Marches Centre of Manufacturing and Technology (MCMT), a Shropshire-centric, industry-led training centre for young engineers. The company will also be sponsoring the Teamwork category at this January’s Motorsport Industry Business Excellence Awards.
James Grainger’s appointment as Vice Chairman of the MIA enables the business to continue to work alongside its peers in motorsport, high-performance engineering and tuning, to ensure everyone is pulling in the same direction.
James commented: “This is both an exciting and important time for the global motorsport industry, with new technologies constantly supporting the development of more efficient and lighter vehicles. As Vice Chairman of the MIA, I can help Grainger & Worrall work more closely with the sector and ensure that our members continue to have an active voice in key industry developments.”
Grainger & Worrall is no stranger to new technologies in the automotive sector. It was the first business in Europe to invest in a specialist 3D sand printer to support the casting of engine components, and pioneered the use of computerised tomography to carry out health checks on its castings, ten years ago. James Grainger added that a willingness to invest in new technologies and implement them into engineering culture is going to go a long way to helping the automotive supply chain to remain competitive amid constant change.
He stated: “Motorsport and the wider automotive sector are facing an exciting time with both legislation and technology developing at a rapid rate. Grainger & Worrall operate at the heart of this, delivering continuous innovation to the market. In my new role as Vice Chairman, I am looking forward to supporting both the MIA and its members in these fast-changing times.”
Commenting on the UK Government’s announcement that the sale of new petrol and diesel cars will be banned by 2040, Edward Grainger, a director at leading automotive castings business, Grainger & Worrall (GW), gives his view:
Praise given to a “remarkable” new engineering training facility.
Grainger & Worrall (GW), played host to an evening event for Institute of Mechanical Engineers (IMechE), organised by Birmingham Young Members Panel. The evening saw the region’s brightest engineers go behind the scenes of the high-quality automotive castings company, to gain valuable insights from GW’s expert engineers.
On 29 June, 2017, Exova the Materials testing partner of GW was acquired by Element Materials Technology. Since that date, the two companies have been working together to integrate their businesses into a single organization that will be known as ‘Element’ in the future.
Effective on or around 14 March 2018 the Bridgnorth Exova locations will start to trade as Element, whilst the legal company name will not change.
Element’s newly combined business makes us the #1 testing provider in the global aerospace and oil & gas sectors, and a market leader in the U.S. transportation and automotive testing market. With 200 laboratories and over 6200 employees worldwide, GW now have access to increased capacity, capability and expertise for all of our existing and future materials testing, calibration, certification needs.
The automotive industry’s response to emissions legislation and consumer expectations has resulted in considerable changes in engine technology recent years. Light weighting and downsizing have led to smaller and more efficient engines, returning fuel economy and emissions figures that have plummeted in the past decade. Throw into the mix the use of CAD software for the design of engines and we’re truly in high-tech territory.
In the light of the chancellor’s funding announcement of £500m a year to support technical training for young people, Bridgnorth-based automotive castings specialist Grainger & Worrall is upbeat about the future. Edward Grainger, a director of the family-owned business, said: “As a significant local employer, we welcome this budget, which is a real shot in the arm for technical skills development in our region.
Faced with the chronic skills shortage, engineering firms should take control of their own futures and establish vibrant apprenticeship and training partnerships. That is the view of Edward Grainger, a director of Grainger & Worrall (GW), the global leader in high performance automotive castings.
Shropshire-based precision castings company, Grainger and Worrall (GW), is looking for the next batch of graduate engineers to kick off their career in manufacturing. This could serve as a big break for aspiring engineers; offering them the opportunity to work with world-renowned brands including Aston Martin, Bentley and even F1 teams, all of whom are customers of GW.
Grainger & Worrall (GW), the UK’s leading provider of high precision casting technologies, opens a state-of-the-art, machining facility at its site in Bridgnorth, Shropshire. The new centre now fully operational, incorporates the existing Telford facility with an additional £5 million investment, centralising the company’s machining operations.
Leading high performance casting specialist Grainger & Worrall (GW) is working in conjunction with Jaguar Land Rover (JLR) and the Advanced Propulsion Centre (APC) to develop a new type of cylinder block that uses plasma coatings to reduce the weight and size of engines.
Aston Martin has confirmed Grainger & Worrall (GW) as its preferred engine castings partner for the new DB11. At the heart of this iconic sports car is the new 5.2 litre twin turbocharged V12. This engine sets even higher performance standards for the latest DB iteration, the cleanest, most fuel efficient, powerful and fastest accelerating model in Aston Martin’s history.
Grainger & Worrall (GW), the UK’s leading provider of high-precision casting technologies, has completed the purchase of a castings facility in Worcester.
We are delighted to be featured in The Engineer Magazine July 2016
As part of an initiative to further expand its small series automotive machining capabilities, the world’s leading total casting solutions provider, Grainger & Worrall (GW), has installed a £1.5m turnkey Flexible Manufacturing System (FMS).
10 May 2016
As suppliers aim to meet quality and reliability benchmarks, AMS speaks to a casting company that regards computer tomography as a game-changer
Global testing and certification group Exova has agreed a new deal with specialist castings provider Grainger & Worrall to deliver a bespoke in-house testing capability.
[New Richmond, Bridgnorth and Stockholm, 17 December 2015] – Engineered Propulsion Systems (EPS) has uniquely leveraged the strength and stiffness of Compacted Graphite Iron (CGI), together with a ‘flat V’ engine design, to establish a new benchmark for general aviation applications. Based on a CGI cylinder block, the 4.3 litre, eight-cylinder design results in a compact, low profile engine package that provides ease of installation, durability and low aerodynamic drag. The use of CGI enabled EPS to engineer a clean sheet Aviation Diesel engine that is setting new standards in weight, size, reliability, and most importantly, fuel consumption. Initial testing of the pre-production engine has demonstrated specific power of 105 horsepower per litre (77 kW/l), resulting in an output of 450 horsepower (332 kW). The installed wet weight of the 450 horsepower diesel engine package is within 45 pounds (20 kg) of alternative 350 horsepower (257 kW) air-cooled turbocharged engines currently used in aero applications.
Now that the dust has settled on Chinese leader Xi Jinping’s visit to the UK, it’s time to assess the true value of Britain’s relationship with the world’s second largest economy. Despite the widespread critique of the UK treatment of the Chinese delegation last month, that’s not reason enough to discount China as a hugely valuable trading partner.
Grainger & Worrall provides prototype, race and automotive casting solutions in aluminium, iron and stainless steel to a global market.
News Source : Shropshire Star Newspaper Cover Page (1) _ 27th June 2015
Following the success of this year’s National Apprenticeship Week (9-13 March), Grainger & Worrall, a leading provider of high-precision casting technologies, has confirmed its commitment to developing the talent of tomorrow. While continuing its upskilling Experts Programme for existing employees, the company also aims to appoint a number of new graduates and apprentices every year. This means that, in a team of 500 staff split between two sites, there will always be individuals undergoing training, work placements or apprenticeships.
Precision-casting technology provider, Grainger & Worrall, has achieved ISO/TS 16949 certification for automotive quality excellence. An acclaimed international management standard, ISO certification is awarded to organisations demonstrating exceptional process delivery when developing, manufacturing, installing or servicing automotive products.
Grainger & Worrall, demonstrated its unrivalled capability in high performance engineering at the Motorsport Industry Association’s (MIA) 2015 defence showcase. The event, which saw over a hundred delegates visit BAE System’s headquarters in Telford, Shropshire, brought together leading organisations from across the motorsport arena to share their expertise with BAE’s defence engineers and supply chain specialists.
The world’s leading total castings solutions provider, Grainger & Worrall, has been named Business of the Year at the Motorsport Industry Association’s (MIA) annual Business Excellence Awards. Held last night (8 January) at Birmingham’s NEC Arena, the national ceremony celebrated the achievements and successes of key automotive players across the UK motorsport sector.
World-leading casting solutions provider Grainger & Worrall has taken home the Manufacturing in Action award at the 2014 Manufacturer (TM) Awards. The globally renowned ceremony, which took place on November 27th, celebrates the very best of UK engineering across a range of sectors.
Grainger & Worrall, took home the prestigious Component of the Year accolade at this year’s Cast Metal Federation (CMF) Awards. Recognising the best of British casting, the event profiles exceptional projects and components delivered by firms from across the country.
Grainger & Worrall was presented with the award in recognition of its bespoke engine block development for the Ford US pickup truck, which features the world’s first CGI petrol production engine. The 2014 ceremony marks the second year in a row that Grainger & Worrall has scooped the Component of the Year – a testament to the world-leading innovation and engineering carried out by the global firm.
Grainger & Worrall, the world’s leading total casting solutions provider, has been awarded a £1.2m grant to further develop its aerospace component production and development capabilities. The match-funded grant, which comes as part of the government’s Sharing in Growth (SiG) initiative, will be used to drive continued innovation at the high-precision engineering expert’s UK headquarters.
As a materials engineer Jack’s work entails providing PFMEA support as well as researching the development of new materials.
What’s your name?
Where do you work?
Grainger & Worrall.
What’s your job title?
How long have you been doing that?
How did you get there?
It’s been quite a journey. After school I worked in a small automotive engine development company making rally engines. While running an engine on our test bed, a piston shot out the side of the cylinder block through a thin walled section, straight by my leg. As a technical task the company asked me to write a report to ascertain the failure mechanism, investigating the scale of deformation, which in turn initiated my interest and awareness in materials science through academia.
Grainger & Worrall is set to showcase its latest enabling technologies and innovative developments in cast prototype manufacturing at this year’s Engine Expo Novi exhibition. Taking place in Michigan, North America, between 28-30 October, the leading powertrain technology trade show will bring the world’s leading automotive professionals together to discuss drive efficiency and fuel economy.
Grainger & Worrall, the world’s leading total casting solutions provider, has been recognised in The Sunday Times’ International Track 200 league table as one of the UK’s fastest-growing export companies. Published last weekend, the independent survey ranks Britain’s top-performing private companies by compound annual growth rate (CAGR) over the past two years.
Grainger & Worrall is delighted to announce the appointment of Matthias Schoeffmann as regional Business Development Manager, based in Munich.
Earlier this week, over 40 senior figures from the UK’s motorsport industry we treated to a rare glimpse inside Grainger & Worrall’s world-class precision casting facility at Bridgnorth. The event, organised by the Motorsport Industry Association (MIA), was part of a series of open days that showcase exceptional organisations working within the global motorsport sector.
Recent changes to Formula One regulations have led to significant innovation and development in the sport, says Phil Ward, head of motorsport at Grainger & Worrall.
Following two highly successful graduate and apprenticeship open days, Grainger & Worrall, has announced a long-term strategic commitment to trainee recruitment.
Regulatory changes in Formula One play a surprising role in fostering innovation, says Phil Ward, head of motorsport at Grainger & Worrall.
New regulations in Formula One have showcased the wealth of innovation within the UK’s motorsport supply chain, says Tom Greenwood of global automotive castings specialist Grainger & Worrall.
After all of the controversy about vehicle reliability, track times and the sound of the new engines has died down, one fact will remain clear; the 2014 Formula One season has demonstrated the excellence of the global industry’s engineering talent. Far from creating unsurmountable barriers, regulatory changes and component restrictions have added a new lustre of technology to the modern starting grid. Indeed pre-test concerns over reliability and performance have, in the most part, been overcome with significant research and development into next-generation solutions.
World-leading castings and machining solutions provider, Grainger & Worrall, has joined the UK’s leading automotive trade association, the Society of Motor Manufacturers and Traders (SMMT). Membership of the prestigious association will allow Grainger & Worrall to proactively support the UK automotive sector while also expanding its global client base.
Grainger & Worrall, the world’s leading suppliers of total casting solutions, has partnered with a leading Swedish engine designer to recreate a twin-cam, 16 valve engine for use with historic Volvos. The twin-cam unit, which was originally developed in 1971, has been produced using the latest engine design capabilities and casting techniques and is for use with Volvo models such as the P1800, 140, 142 and 145, as well as the PV544.
Grainger & Worrall, the world-leading total castings solutions provider, has won the prestigious Cast Metals Federation’s (CMF) 2013 UK Component of the Year Award for its Cosworth CA cylinder head. Designed for the highly-demanding environment of Formula 1, the lightweight aluminium cylinder head pushes the boundaries of automotive design, delivering championship-winning performance and reliability by means of a unique, low pressure sand-casting manufacturing process.
Grainger & Worrall, the UK-based, world-leading motorsport castings provider, presented a wide range of casting competences, validation and associated engineering services at Professional MotorSport World Expo 2013, 12 – 14 November, Cologne, Germany.
Castings solutions provider, Grainger & Worrall, is showcasing the company’s latest range of casting competences, validation and associated engineering services at Engine Expo North America 2013, 22 – 24 October, Novi, Michigan, stand E234.
Grainger & Worrall, has gained ISO 14001 certification across all of its sites following the recent accreditation of its Telford facility. The latest ISO certification follows the Shropshire firm’s continued drive for environmental best practice across all of its sites and coincides with a £400,000 investment in infrastructure for a new natural gas grid connection at the company’s Bridgnorth facility.
The world’s leading total castings solution providers, Grainger & Worrall, has appointed Matthew Snelson to its senior team, as it looks to drive forward its ambitions in the automotive, motorsport, defence and aerospace sectors.
Shropshire castings company, Grainger & Worrall, the world’s leading total castings solutions provider, has been included in the fourth annual Sunday Times Fast Track International 200 survey. Published this weekend, the league table ranks Britain’s private companies with the fastest-growing international sales.
SHROPSHIRE-based casting company, Grainger & Worrall, is targeting growth by securing new work in the defence sector.
Shropshire castings company, Grainger & Worrall, has invested over £500,000 in an S-Print HHS 3D sand printer. The technology enables the Bridgnorth-based company to provide its customers with an additional innovative and highly advanced rapid prototyping solution.