Sarginsons Foundary229 Scaled
Our Story

93 Years of Casting Technology

Founded by three brothers in 1933, as a sand pattern maker, Sarginsons has been innovating for the British automotive industry, particularly with thin wall section castings and lightweighting, as the aluminium foundry it is today.

After being bombed in WW2, having manufactured aircraft engine components and ARP helmets, the company moved to an old trouser factory, with a company pond, in 1950. Alongside casting taps for Norman Wisdom's dancing shoes, the company worked on almost every British car before, unfortunately, casting a number of components for DeLorean DMC 12 in 1983.

Today, Sarginsons is an aluminium foundry amongst four companies that comprise the Nudation Group. All companies work seamlessly on Sarginsons unique DfM+ service, but all maintain their own identities to ensure they remain at the cutting edge of their industries.

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Our Strategy

Sarginsons seek to understand all aspects of aluminium casting technology, as a means of producing stronger, greener, larger, and lighter cast components. The massive economies and significant performance improvements achieved, make us an essential gateway and first port of call for structural aluminium components & assemblies. 

Sarginsons constantly work with Universities and OEMs, across the world, to further the immense possibilities that advanced casting technology promises. The dream is total liquid metal engineering, where casting's inherent ability to adopt any design is fully exploitable.

Sarginsons most recent breakthroughs includes the world's only true digital twin simulations, high strength recycled aluminium, TYE manipulation, and the ability to create sand cast prototypes with the same mechanical performance as production components.

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Sarginsons Industries

Sarginsons has been a full service aluminium foundry and pattern maker since 1933 when it quickly established a reputation for innovation which has driven, an 80 year involvement with the UK automotive industry.

Sarginsons specialises in high integrity, complex castings from Low Pressure, Gravity and Sand casting, particularly in the automotive and aerospace industries, but its true calling is in finding solutions, usually through technology, to otherwise insurmountable casting problems.

Sarginsons is not your everyday foundry. It specialises in advancing casting technology as a means of solving complex and challenging casting dilemmas, like lightweighting, the consolidation of components and enhanced TYE performance. 

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Numachine : A Casting Machinist

The CNC machining of castings is a specialist skill. It requires a detailed knowledge of tooling, datum strategies, and fixturing, as well as an in depth understanding of casting, heat treatment, and coating options.

Sarginsons view CNC machining as an integral part of the casting design process, with well planned tolerances and optimised CNC pathways being critical to finding the perfect casting design.

Numachine, a Sarginsons subsidiary, is one of the best. With 5 axis to 1.6m it is capable of handling the largest of castings, whilst its years of solving the most complex of machining problems positions it ideally to solve the next impossible challenge.

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Pattern Solutions

Having a sand pattern making subsidiary is critical to a responsive and innovative casting service. It's not only about being able to produce original, solution driven, patterns, it's also about being able to do so immediately.

Pattern Solutions provides a rapid turnaround service that perfectly complements Sarginsons iterative approach to casting design. The numerous tweaks and modifications required to refine, test and explore optimum design solutions demand in house production - particularly when seeking perfect production prototypes.

Pattern Solutions produces all of Sarginsons sand patterns but also its CNC, X-Ray and heat treatment fixturing, utilising 3D printing as well as traditional fabrication techniques.

Our People. Intelligent Aluminium Thinking

The excitement may be all about the technology, but the reality is all about our people. 

Annette Milton

Finance Director
Annette Milton

Ashley Stafford

Commercial Director
Ashley Stafford

Rick Davies

Engineering Director
Rick Davies

Gavin Shipley

Technology Centre Director
Gavin Shipley

Steve Carter

Quality Manager
Steve Carter

Your Challenges. Our Solutions.

Challenges are the lifeblood of Sarginsons. They're the kernel of our R&D, the reason for our existence, the essence of who we are. From the foundation of the company we have been solving problems, realising ambitions, smashing assumptions and changing the possible. Problems are our doorways to progress.

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Technology
Foundry
Consultancy
Challenges

Lighter, Better Castings

In being able to accurately simulate and manipulate TYE mechanical strength, at any point across a components form, Sarginsons can exploit the extraordinary ability of topological optimisation to shed mass whilst enhancing mechanical performance.

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Lighter, Better Castings
Services

World Leading Technology

Sarginsons technology is world leading. It's unique ability to map heterogenous TYE data to FEA meshes allows the full potential of topological optimisation, giga-casting and dynamic testing to be realised for the first time. It's totally changed casting.

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World Leading Technology
Solutions

Larger Castings are the future

Casting entire sections of cars in one piece makes sound economic sense. With the development of several casting technologies, many pioneered by Sarginsons, they can also be lighter greener and cheaper.

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Larger Castings are the future
Challenges

Improving TYE

Increasing TYE mechanical performance, even in sand cast prototypes, is a Sarginsons speciality. A whole range of novel technologies covering every aspect of the casting process can be deployed.

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Improving TYE
Services

Pioneering Aluminium Foundry

Sarginsons is a high integrity, aluminium foundry covering low pressure, sand and gravity casting techniques, that has forged new frontiers in lightweight, complex and geometrically challenging castings.

Learn More
Pioneering Aluminium Foundry
Solutions

Shaped Castings for Aerospace

Sarginsons five years of research into casting aerospace components has produced the technology, such as digital twin simulations, that can produce stronger, greener, and cheaper components through traditional casting techniques.

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Shaped Castings for Aerospace
Challenges

Reducing Costs

Casting has massive potential for cost reductions. It starts with great component design but there's a multitude of other approaches that combined, represent potentially massive overall economy.

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Reducing Costs
Services

Casting Consultancy

Sarginsons consultancy fills the gap between OEM product designer and casting foundry by combining its world leading casting technology with it's hand on foundry knowledge. This results in cheaper, easier, lighter and less expensive cast components.

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Casting Consultancy
Solutions

The Perfect Cast Prototype

Prototypes are not production representative as different manufacturing processes result in differing mechanical performance. Sarginsons can manipulate mechanical performance, particularly in sand castings, to create prototypes that exactly mimic production parts. A huge advantage.

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The Perfect Cast Prototype
Challenges

Perfect Prototypes

Industrialising castings, whose prototypes are made using different processes, is challenging. Sarginsons has avoided the issue by being able to cast prototypes with the same mechanical characteristics as production components. A real advantage.

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Perfect Prototypes
Services

University Research

Sarginsons has worked on research projects with Sheffield, Birmingham, Warwick, Imperial and several other universities, alongside many automotive and aerospace OEMs. We're always learning.

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University Research
Solutions

The 24 Hour Casting

Casting TYE mechanically compliant prototypes from CAD, in under 24 hours is feasible, as 3D printed moulds and cores alongside digital twin simulations and Smart Cooling can bypass bottlenecks, whilst ensuring full mechanical integrity.

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The 24 Hour Casting
Challenges

Lighter, Better Castings

In being able to accurately simulate and manipulate TYE mechanical strength, at any point across a components form, Sarginsons can exploit the extraordinary ability of topological optimisation to shed mass whilst enhancing mechanical performance.

Learn More
Lighter, Better Castings
Challenges

Improving TYE

Increasing TYE mechanical performance, even in sand cast prototypes, is a Sarginsons speciality. A whole range of novel technologies covering every aspect of the casting process can be deployed.

Learn More
Improving TYE
Challenges

Reducing Costs

Casting has massive potential for cost reductions. It starts with great component design but there's a multitude of other approaches that combined, represent potentially massive overall economy.

Learn More
Reducing Costs
Challenges

Perfect Prototypes

Industrialising castings, whose prototypes are made using different processes, is challenging. Sarginsons has avoided the issue by being able to cast prototypes with the same mechanical characteristics as production components. A real advantage.

Learn More
Perfect Prototypes
Challenges

Casting Problems?

Sarginsons remedies problems in existing castings, by deploying its full range of novel technologies, in one central hub.

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Casting Problems?
Challenges

Simulations Improve Realities

Sarginsons have developed the world's first simulations of TYE performance in castings. This changes everything, by freeing casting design from the deadening hand of virtual uncertainty to the certainty of a new virtual reality.

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Simulations Improve Realities
Challenges

Supply Chain Resilence

To address the issue of supply chain resilience, Sarginsons has developed a virtual solution that enables emergency, short run casting, without the administrative burden and costs of dual sourcing.

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Supply Chain Resilence
Challenges

One Piece Castings

Merging components into a one-piece casting is common sense. Sarginsons unique ability to simulate mechanical performance at any point on a cast form allows it to lightweight larger castings precisely.

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One Piece Castings
Challenges

Near Zero Carbon

Sarginsons is on a mission to become the world's first zero carbon foundry. It has developed new zero carbon aluminium alloys and is now investing to ensure all processes avoid carbon but remain competitive.

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Near Zero Carbon
Services

World Leading Technology

Sarginsons technology is world leading. It's unique ability to map heterogenous TYE data to FEA meshes allows the full potential of topological optimisation, giga-casting and dynamic testing to be realised for the first time. It's totally changed casting.

Learn More
World Leading Technology
Services

Pioneering Aluminium Foundry

Sarginsons is a high integrity, aluminium foundry covering low pressure, sand and gravity casting techniques, that has forged new frontiers in lightweight, complex and geometrically challenging castings.

Learn More
Pioneering Aluminium Foundry
Services

University Research

Sarginsons has worked on research projects with Sheffield, Birmingham, Warwick, Imperial and several other universities, alongside many automotive and aerospace OEMs. We're always learning.

Learn More
University Research
Services

World Leading Technology

Sarginsons technology is world leading. It's unique ability to map heterogenous TYE data to FEA meshes allows the full potential of topological optimisation, giga-casting and dynamic testing to be realised for the first time. It's totally changed casting.

Learn More
World Leading Technology
Services

Pioneering Aluminium Foundry

Sarginsons is a high integrity, aluminium foundry covering low pressure, sand and gravity casting techniques, that has forged new frontiers in lightweight, complex and geometrically challenging castings.

Learn More
Pioneering Aluminium Foundry
Services

University Research

Sarginsons has worked on research projects with Sheffield, Birmingham, Warwick, Imperial and several other universities, alongside many automotive and aerospace OEMs. We're always learning.

Learn More
University Research

Some Of Our Valued Clients

Our University and Research Partners

Our Casting Awards

Innovation 2022 Award
Company Award
Casting Award (1)
Innovation Award (1)

Latest Innovations & Updates from Sarginsons

Sarginsons use AI & Topology to create a new bike frame.
14th September 2023

Sarginsons use AI & Topology to create a new bike frame.

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PIVOT: Sarginsons Lead & Win £6m Research Grant
17th September 2024

PIVOT: Sarginsons Lead & Win £6m Research Grant

Read More
Explore more Articles & Research

A Success Story. Built on failure.

There's no such thing as failure, only another lesson learnt. It is this attitude that defines Sarginsons. We know there's a solution, it's just a little difficult to find sometimes. We know, because we've found plenty.

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Email: info@sarginsons.co.uk

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