MRT Castings Ltd

Our high pressure die casting service provides the quickest route from molten metal to completed component.

This is done by injecting molten metal (whether it be aluminium die casting or zinc die casting) into a hardened tool steel mould and allowing it to solidify under pressure before ejection. 

This high pressure die casting process allows fast, precise, cost effective production of aluminium or zinc die castings, meeting the needs of hi-tech industries where product appearance and dimensional tolerances are critical but volumes are not always large.

We have high pressure die casting machines with locking forces of between 220 and 530 tonnes. All have microprocessor control and the latest include computerised real-time shot control, automatic ladling and die-spray, and automatic casting extraction and cooling.

Our gravity die casting service employs a number of steps and involves cast iron moulds allowing aluminium and zinc castings to be produced more accurately and cheaply than sand casting.

Our gravity die casting service has a number of added advantages including the following areas:

• Process Control - comprehensive set-up records and quality data ensure consistent production and reduce set-up time.
• Quality - quality is achieved by pride in workmanship, backed up by an excellent quality system to ISO9001:2008.
• In-house toolroom - routine tool maintenance, breakdowns and modifications can all be undertaken in-house to reduce tool down time.
• Tool and casting design - our expertise can help you optimise designs, eliminating elements which add unnecessary costs. Thus we provide the benefits of automated production without high-cost tooling. Innovative press trimming tool design can also help to reduce finishing costs.  Where required, we can also provide filling and solidification simulations using the latest computer technology.

We offer a high pressure die casting service meaning a shorter route from the molten metal to the completed part. 

Many high pressure die casting foundries only offer their services for high-volume orders, claiming that lengthy set-ups make the process prohibitive to small quantities of zinc or aluminium.

We have optimised tooling preparation and set-up operations to make the process more accessible to customers who require only small quantities of aluminium or zinc castings, but whose applications would benefit from the excellent dimensional and cosmetic properties of pressure die casting. We can provide the complete service, whether you require a batch of 10 or 10,000.

Sand casting for non ferrous castings offers you the simplest way for the production of non ferrous castings. This method involves pouring molten zinc, aluminium or copper into a sand mould. 

The sand casting for non ferrous castings process is chosen for the production of:

• Small numbers of castings
• Complex shaped casting requiring intricate cores
• Large non ferrous casting

Advantages of sand casting include:

• Low tooling costs
• Largest casting sizes achievable
• Very low gas porosity is possible
• General versatility of the process is good 

Limitations include:

• Low casting rate
• 3-5mm minimum wall thickness
• Poor linear tolerance (e.g. 4mm/m)
• Rough surface finish
• Coarser grain size than gravity die casting

We can provide all your toolmaking and design solutions in one package. We have been designing, manufacturing and running die casting tooling for many years. We have a great deal of experience in optimising component and tool designs to achieve the best toolmaking results. 

As part of our toolmaking and design service, we use the latest Solidworks CAD software to support us. We can offer computerised filling and solidification simulation where required.

 

We have an extensive and contemporary CNC machining facility and it is at the very core of the company's operations. 

We have an experienced team of specialists in CNC machining castings and understand the casting process itself, so they know the important inspection aspects of working on cast components. In terms of machine tools, we have some of the fastest and most versatile machines available. Our ongoing investment programme ensures that the latest technology is employed to minimise production costs and enhance product quality.

In a market where customers require the shortest possible lead times, the benefits of finding a single source who can cast, machine and finish components can slash lead times and greatly reduce the logistic and management costs of dealing with several subcontractors. Most critical to your competitiveness, however, is that the machine shop which you choose to rely on has the best kit and skilled staff to optimise the quality and productivity of their processes.  We are that machine shop.

We know that our customers are all specialists in their fields. They need a reliable supply of high-quality components, on time, and ready for production. We offer a complete package including metal surface finishing leaving you free to concentrate on your application of the component.

To complement the extensive services of our foundry and machining divisions, we supply a wide range of metal surface finishing processes.

These include:

• Alochroming
• Anodising
• Assembly
• Ball Burnishing
• Chromating
• Degreasing
• Electroplating
• Impregnation
• Painting
• Phosphating
• Polishing
• Powder Coating
• Silk Screen Printing
• Shotblasting
• Vibratory Finishing

We are experts in managing the supply chain of components through the various stages of production. Bespoke computerised scheduling software manages the entire process, providing traceability for every batch and ensuring we stick to our delivery promises.

When problems do occur and customer requirements change, our small, friendly team are always ready to respond. In everything we do, we deliver the high level of service you would expect from a family business which has been successful for over 50 years.