Producing large, durable structural parts with sand casting

Grainger and Worrall develop large, precision sand castings required for structural parts.

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High-performance sand castings for large structural parts.

Structural parts require castings that are durable, accurate and strong. We use our materials knowledge, prototyping experience and sand casting expertise to create innovative, large BIW (Body in White) automotive components. 

Sand casting allows us to create the complex, lightweight and thermally stable structural parts required across vehicle applications. Our quality control and engineering experience allow us to do this reliably and accurately - for every single project.



LIGHTWEIGHT, COMPLEX, large structural sand castings


  • We create large scale, structural BIW (Body in White) automotive castings, including two metre long automotive torque tubes and commercial transmission housings.

  • We use the flexibility of sand casting to create complex geometries in a single, net shape and in a range of alloys optimised for structural parts.

  • Our technological investment and capabilities such as in 3D sand printing allow us to create castings quickly, meeting tight lead times.

  • We develop unique alloy chemistries specifically for lightweighting, durability, elongation and thin-walled components.

GW Moon Buggy
  • Our Magma simulation software allows us to prototype properties prior to production, reducing unnecessary weight and overengineering in structural automotive components.

  • We create bespoke aluminium alloys, maximising properties required in structural part castings such as ductility, strength and thermal stability.

  • Our inspection and validation capabilities include CT scanning, GOM and dye penetration to ensure we meet tight specifications and tolerancing requirements. This guarantees high integrity sand castings for each and every structural part.



Want more details? Take a look at our case studies.

By the way, most of what we do and who we work with isn't in the public domain.  If you'd like to talk specifics about your project, get in touch!

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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.

Queens award 2020 RandD 100 ISO 14001 H&S Picture1

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


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