Queen's Award for Enterprise

Foundry Process Consultancy

Our experts can help you throughout your project lifetime.

Foundry process consultancy brings together the skills in the manufacture of tooling and casting prototypes. This combined with its knowledge and expertise of simulation techniques, project management, product launch and manufacturing process development offers customers a complete ‘design to production’ solution.

We have worked together with the world’s leading design consultancies taking concept designs through to mature production.

Foundry process design, the optimisation of foundry tooling and process simulation is core to our engineering service offering.

The Grainger & Worrall casting expertise leads the world in high integrity complex sand castings, supplying automotive OEM’s, Tier 1 suppliers and blue-chip aerospace customers.

Advanced in house modelling of metal flow and solidification at the prototype phase provides our experts with the key information to permit optimised tooling design, casting methods and subsequently transfer this knowledge through to large scale production runs.


We have designed and commissioned multiple new foundries worldwide, our engineers have decades of experience in their field.

Our foundry design consultancy has worked with European, North and South American and Asian operations. Activities include die-casting design methodology for passenger cars, medium and heavy duty diesel engines, racing, performance components and unconventional engine technology.

We can support you in foundry design, computational analysis of cast components and manufacturing processes such as metal flow and solidification, microstructure, mechanical properties and residual stress, core blowing and gassing. In fact with all aspects of process optimisation for metal casting such as metallurgy, running and feeding systems, core and mould making, mould assembly and handling, metal melting and handling, casting finishing operations.