Aluminium Die CastingAluminium Gravity Die Castings

Aluminium Die Casting

Aluminium Die Casting Brophy Castings are specialist aluminium die-casters catering to a UK client base. The gravity die-casting process allows the production of consistent castings incorporating complex internal structures by using a combination of metal dies and sand cores with a flexibility in production that other processes such as pressure die casting cannot offer. With over 30 years experience in the aluminium gravity die-casting business there are not many problems that we have not come across.

Die-casting allows for extremely accurate mouldings to be created in medium volume at a very cost effective rate. For batches of 50-5000 die-casting can often be shown to reduce costs considerably compared to components currently machined. If you have a prototype or a production component you are machining and want to increase production and in turn reduce costs, then please feel free to call us for an informal conversation. Our prices cannot be beaten.


Castings can be made up to 1000mm tall and approximately 700mm wide and upto 10kg. All castings are hand poured from Half Tonne 48KVA Morgan Temperature Controlled Bale Out Resistance Furnaces. Most of our work is in LM6 & LM25. Die cast moulds produce an accurate component with a very good surface finish which often does not need any secondary work. The surface finish can also, to some extent, be modified by the type of release agent used.

Cast-In Inserts

Pre-threaded bosses, threaded studs and high strength bearing surfaces can be incorporated into the casting before the metal is poured.

Sand Cores for Aluminium Die Casting

Sand Cores

Sand cores can be used to cast awkward & complex internal shapes including lipped cavities and internal bends.

Silica sand cores can be made up to 300mm2 to almost any complexity.

Release Agents

We offer 4 types of release agent for varying types of finish.

The Dycote permanent mould coatings promote proper mould filling and release, improves the metallurgical properties and surface finish of aluminium castings and protects the die, extending its life.

Medium Volume

Medium Volume

Die-casting is ideal for medium volume work. The moulds which are machined from cast iron are suited for a production life of 200,000+, much longer than sand casting and with drastically lower costs than pressure die-casting.

Depending on the size of the component and the mould cavities we can produce over 500 units per day from each individual furnace. Production levels range from 50 to 50000.


Working closely with our clients we can help develop prototype components and moulds working from drawings, existing parts or design briefs.


Castings can be supplied in sacks, packaged in tissue paper or bubble wrap, pallet stacked or crated, according to customer requirements.


Our strict quality control procedures are carried out on raw materials as well as during the manufacturing processes to ensure that all our customers receive only the best. Certificates of analysis & conformity and batch traceability is offered where required. We also ensure that all of our subcontractors provide a top grade service and inspect all goods prior to dispatch and upon return.

Brophy Castings Ltd - Building 15 - Soho Mills - Wooburn Green - Buckinghamshire - HP10 0PF - UK
Tel: 01628 525068 - Fax: 01628 525129 - E-mail:

Aluminium Gravity Die Casting - Aluminium Castings - Aluminium Die Cast Finishing- Aluminium Casting - Sand Core Die Casting
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