Know-How Archives - Maybrey

The Artist and the Design Process

gabi.huiam.net — Thu, 05 Dec 2024 17:24:17 +0000

The Black Renaissance sculptures began not in a foundry, but in the intersection between history, digital technology, and one artist's determination to represent the unrepresented.

Rayvenn Shaleigha D'Clark

Rayvenn Shaleigha D'Clark is a British sculptor whose practice combines digital and traditional methods. Her work is concerned with representation, identity, and the public landscape: who gets to be depicted in permanent material, and what that tells us about whose stories a society considers worth preserving.

For the Black Renaissance commission, D'Clark was given the brief to create five monumental figures representing anonymous individuals whose histories are part of the story the Freedom Monument Sculpture Park tells. She brought to the commission a process that is both technically sophisticated and deeply human.

From Research to Digital Model

D'Clark's starting point was research: into the lives, the culture, and the visual language of the communities the sculptures would represent. From that research, she developed digital models using professional sculpting software, working at a level of surface detail that was extraordinarily demanding.

The surfaces of the Black Renaissance sculptures carry fine physiological and cultural detail: features, textures, and references that had to be present in the final bronze for the work to be what it needed to be. Some of this detail pushed the software to its limits. Where the digital tools could not fully resolve what D'Clark needed, physical intervention, sketching, and dialogue between the artist and our casting team filled the gap.

The Foundry Conversation

What made this project work was not just the technology. It was the conversation between the artist and the foundry. D'Clark understood that a casting has its own constraints: minimum wall thicknesses, draft angles, the way metal flows and solidifies. Our team understood that a work of art has its own non-negotiable requirements.

The result of that conversation was a casting approach that used 3D printed sand moulds produced directly from D'Clark's digital files. This allowed us to preserve the surface detail that the artist had worked to create, without the compromise that conventional pattern tooling would have forced.

52 Unique Castings

Each of the five sculptures was cast in multiple segments: 52 unique castings in total, each from its own 3D printed mould. No two moulds were identical. The assembly of those segments into the finished sculptures was carried out by Millimetre, West Sussex, whose fabrication skill was as important to the final result as the casting.

Seeing the completed sculptures installed at the Freedom Monument Sculpture Park is, for everyone who worked on this project, a reminder of what the trade of casting is capable of when it is placed in service of something worth making.

Read the technical case study

Read about the message behind the project

Instagram: @rayvenndclark_art

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What is Aerospace Casting

gabi.huiam.net — Wed, 13 Nov 2024 16:37:54 +0000

Aerospace casting is not a different process from other casting. It is the same fundamentals: pattern, mould, pour, solidify, inspect. What makes it different is the framework within which every step is controlled, documented, and verified, and the consequence of getting any of it wrong.

Maybrey Precision Castings has held unbroken aerospace approval since 1937, when the Air Registration Board first approved our foundry for aviation work. That certification is now AS9100 Rev D. No other UK foundry has held a longer continuous record of aerospace approval.

What Aerospace Casting Requires

Aerospace castings must meet tight dimensional tolerances, specified mechanical properties, and full chemical traceability. At Maybrey, our aerospace work is produced on a dedicated line using only new PepSet silica sand. Aluminium only is melted on this line: cross-contamination with other alloys is not permitted.

Aerospace Alloys

We cast in the full range of aerospace specification aluminium alloys, including BS2L99, BSL169, A356, A357, and BSL119 (RR350). Every incoming ingot is tested on our calibrated Spectro MAX X spectrometer before use. No ingot enters production that has not been analysed and confirmed.

Traceability: From Ingot to Despatch

A router card follows every aerospace casting through the facility from moulding to despatch. Each processing step, the operator, date, and any non-conformances are recorded. Certification is issued from our in-house quality database system once all required processing and testing is complete.

Chemical and Mechanical Testing

Releasing a casting under AS9100 requires both chemical analysis and mechanical testing. Chemical analysis is carried out using Spectro MAX X spectrometers: at incoming inspection, as a daily foundry check, and as a final analysis for the certificate of conformity. Mechanical testing is carried out using our 0.5% resolution 100 kN WDW-100-E Tensile Tester, compliant to BS EN ISO 7500-1:2018.

NADCAP Sub-Contracted Processes

Non-destructive testing (NDT)
Hot isostatic pressing (HIPping): eliminates internal porosity in safety-critical castings
X-ray inspection
Dye penetrant testing

An Illustrative Application

One application that illustrates the capability of the process is the Ram Air Turbine (RAT) system: the emergency power generation unit deployed in the event of engine failure on certain aircraft. Safety-critical by definition. This is the standard to which our aerospace casting is held, across every component we produce for this sector.

Explore our Aerospace & Defence capability

View our accreditations

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What is Silicon Bronze Casting?

gabi.huiam.net — Wed, 11 Sep 2024 16:02:21 +0000

Silicon bronze is a copper alloy in which silicon is the primary alloying element. It produces castings of exceptional quality: corrosion-resistant, easily welded, capable of a long-term patina, and with a warm golden colour that no other casting alloy quite matches. For artists, sculptors, and architects working in bronze, it is usually the material of first choice.

At Maybrey Precision Castings, silicon bronze is central to our art foundry work. We have cast it for monumental public sculptures, architectural commissions, and heritage restoration.

Properties of Silicon Bronze

Corrosion resistance: performs exceptionally well in atmospheric and outdoor conditions without sealing or protective coating
Weldability: can be welded with low risk of hot cracking, ideal for sculptures cast in segments and then assembled
Wall thickness tolerance: accommodates variations without significant loss of mechanical integrity
Patina: develops a rich, stable patina over time; colour can be controlled chemically from gold through green
Detail retention: casts finely, reproducing surface detail with high fidelity

How Silicon Bronze Casting Works at Maybrey

Silicon bronze is cast using the sand casting process. For work involving complex organic forms or pronounced undercutting, we use 3D printed sand moulds: produced directly from a CAD or scan file, without building a physical pattern. It was central to our Black Renaissance project, where each of the 52 unique sculpture segments required its own mould, and to our production of Mother Vérité, London's first public statue of a postpartum woman.

Post-casting, silicon bronze can be treated with a range of finishes: patination (both natural and chemical), polishing, grinding, and protective wax or lacquer coatings.

Applications

Monumental and fine art sculpture
Architectural bronze: door furniture, plaques, decorative panels, and railings
Heritage restoration: reproducing existing bronze or copper work
Marine hardware: silicon bronze is highly resistant to saltwater corrosion

Read how we used silicon bronze for the Black Renaissance sculptures

Read how we cast Mother Vérité, London's first postpartum statue

Talk to us about your silicon bronze project

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What is Heat Treatment

gabi.huiam.net — Tue, 11 Jun 2024 17:43:25 +0000

Heat treatment is a controlled process of heating and cooling a casting to alter its microstructure and, with it, its mechanical properties. It is carried out after the casting has cooled and been removed from the mould, and before it moves to final inspection and despatch.

Not every casting requires heat treatment. But for applications where specific mechanical properties, stress relief, or dimensional stability are required, it is an essential part of the production process. At Maybrey, we carry out heat treatment in-house as part of our post-process capability.

The Main Types of Heat Treatment

Stress Relief and Annealing

Casting involves rapid solidification from high temperatures, which can leave residual stresses in the material. These stresses can cause distortion, cracking, or dimensional instability during subsequent machining or in service. Stress relief annealing heats the casting to a moderate temperature, holds it there long enough for the stresses to dissipate, and then cools it slowly. The result is a more stable, dimensionally consistent casting.

Full annealing takes the casting to a higher temperature and cools it more slowly still, producing maximum softness. This is used where the casting needs to be worked further, or where machinability is the priority.

Solution Treatment and Ageing

For aluminium alloys, heat treatment is frequently used to develop the material's full mechanical potential. Solution treatment heats the casting to a temperature at which the alloying elements dissolve into the aluminium matrix, then quenches it rapidly to retain them in solution. This alone produces a supersaturated and relatively soft condition.

Ageing, either at room temperature (natural ageing) or at elevated temperature (artificial ageing), causes the dissolved elements to precipitate out as fine particles within the matrix. This precipitation hardening is what gives aerospace aluminium alloys their characteristic combination of low weight and high strength. The T6 condition, solution treated and artificially aged, is the most widely used specification for aerospace aluminium castings.

Heat Treatment at Maybrey

We carry out stress relief, annealing, solution treatment, and ageing in-house for both ferrous and non-ferrous castings. Our heat treatment operations are covered by our ISO 9001:2015 and AS9100 Rev D quality management systems. For aerospace castings, heat treatment procedures are specified at the contract review stage and form part of the full traceability record that accompanies each batch.

Explore our full Post-Process capability

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Understanding Carbon Neutrality: What does it mean to be carbon neutral?

gabi.huiam.net — Tue, 23 Apr 2024 15:31:59 +0000

You may have searched for 'carbon neutral'. We use the term Carbon Net Zero, and there is a reason for that. This post explains what Carbon Net Zero means, how it differs from other terms in common use, and where Maybrey Precision Castings stands on the journey towards it.

Carbon Net Zero: What It Means

Carbon Net Zero describes a state in which the carbon emissions produced by an organisation have been reduced to as close to zero as possible, with any remaining emissions that cannot yet be eliminated balanced by an equivalent amount of verified carbon removal.

The critical word is 'reduced'. Carbon Net Zero is primarily about cutting actual emissions at source: through energy efficiency, cleaner energy, smarter logistics, and better supply chains. Offsetting plays a role, but it is not a substitute for genuine reduction.

How Does It Differ from Carbon Neutral?

The terms are used interchangeably in some contexts, but there is a meaningful distinction. 'Carbon neutral' can be achieved primarily through purchasing carbon offsets, without making significant reductions to actual emissions. Carbon Net Zero, by contrast, requires demonstrable, measurable reduction of emissions as the primary mechanism, with offsetting as a secondary tool.

We use Carbon Net Zero because it accurately describes what we are doing: reducing our actual emissions at source, not simply compensating for them.

The Science-Based Framework

The Future Net Zero (FNZ) programme that Maybrey and the Caro Group participate in is aligned with the United Nations Framework Convention on Climate Change (UNFCCC) Race to Zero campaign. The key targets are: a 50% reduction in greenhouse gas emissions by 2030, and full Carbon Net Zero by 2050. Progress is independently verified at Silver, Gold, and Platinum award levels.

Why It Matters for Manufacturing

Manufacturing accounts for a significant proportion of global carbon emissions. Customers in aerospace, construction, and the public sector are increasingly required to demonstrate reductions in their supply chain emissions (Scope 3). Choosing suppliers who are independently certified on Carbon Net Zero is one of the most direct ways to meet those obligations.

Every casting Maybrey produces comes from a facility operating within a verified Carbon Net Zero programme. That is a direct benefit to the supply chain sustainability of every customer we work with.

Read about our carbon reduction journey

Our full sustainability commitment

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What is Sand Casting?

gabi.huiam.net — Wed, 03 Jan 2024 19:20:04 +0000

What is Sand Casting?

Sand casting is one of the oldest forms of metalworking still in widespread use: a process of forming metal parts by pouring molten metal into a cavity shaped by compacted sand. The mould is broken open after the metal has cooled and solidified, revealing the casting inside. The sand is recycled and the process begins again.

It sounds simple. In practice, it is anything but. The choice of sand, binder, and mould construction method determines the surface quality, dimensional accuracy, and structural integrity of everything that comes out. At Maybrey Precision Castings, we have been refining that process for 177 years.

How Sand Casting Works

The process begins with a pattern: a physical model of the casting, made from wood, resin, or metal, built to account for the shrinkage of the metal as it cools. The pattern is pressed into compacted sand to create the mould cavity. Cores, made separately from sand, are set into the mould where hollow sections or internal features are needed.

Once the mould is assembled and any cores are set, molten metal is poured at the correct temperature for the alloy. Pouring too fast or too slow, at the wrong temperature or with poorly designed running and gating, introduces defects. Getting it right consistently is where experience matters.

After solidification and cooling, the mould is broken apart, the casting is knocked out, and the process of fettling begins: removing the running system, cleaning the surface, and inspecting for defects before the casting moves to post-processing.

Materials

Sand casting is one of the few processes that can handle the full range of casting alloys in a single facility. At Maybrey we cast in:

Grey iron, ductile iron, and SG iron: the workhorses of industrial and heritage casting
Aluminium alloys: lightweight, corrosion-resistant, essential for aerospace and commercial applications
Copper-based alloys, including silicon bronze: used in architectural work and sculpture where warmth of colour and long-term patina matter

What It Can Produce

The versatility of sand casting is its defining quality. A single foundry with the right capability can produce a 750 kg iron casting for a heritage restoration project and a 5 kg silicon bronze sculpture for a public art commission, using the same fundamental process.

At Maybrey, we use sand casting to produce components for aerospace and defence, architectural and heritage restoration, art commissions, and commercial engineering: rail, marine, utilities, and buildings products. Castings can be produced as single pieces, small batches, or in ongoing production runs.

Advantages of Sand Casting

Material versatility: suitable for iron, aluminium, copper-based alloys, and more
Size range: castings from a few grams to 750 kg in iron, 250 kg in non-ferrous
Low-volume capability: a single casting is as achievable as a batch of fifty
Complex geometry: cores and split-line patterns allow for undercuts, hollow sections, and intricate forms
No minimum order: sand casting does not require the volume commitment that die casting tooling demands

Limitations Worth Knowing

Sand casting produces a rougher surface finish than gravity die or investment casting. For applications where a precise surface finish is critical, post-process work: machining, shot blasting, or grinding, is usually required. At Maybrey, this post-processing is carried out in-house.

Sand Casting at Maybrey

Our sand foundry in Aylesford operates eight Omega sand mixers covering both our iron and aluminium sections. We supply many castings fully machined, heat-treated, and finished, reducing your supply chain to a single point of contact. All production is carried out under ISO 9001:2015 and, for aerospace and defence work, AS9100 Rev D.

Explore our Sand Casting capability

See sand casting in practice: SG Iron Lampposts for Regent's Park

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What is Aliminium Gravity Die Casting?

gabi.huiam.net — Wed, 15 Nov 2023 15:03:30 +0000

Gravity die casting is a permanent mould casting process: molten metal is poured into a precision-machined steel die, fills the cavity under gravity, solidifies, and is then extracted when the die is opened. The same die is used repeatedly, producing castings with consistent dimensions and a better surface finish than sand casting.

The word 'permanent' is the key difference from sand casting. In sand casting, the mould is destroyed to retrieve the casting. In gravity die casting, the mould stays, and its quality improves with use as the die surface conditions. This repeatability makes gravity die casting well suited to components that need to be produced in identical form across a production run.

How Gravity Die Casting Works

The process begins with die preparation: the steel tool is coated with a refractory wash to prevent the aluminium from bonding to the die surface, and heated to the working temperature for the alloy being cast. This temperature control is important: a die that is too cold produces poor fill and cold shuts; too hot, and the casting's mechanical properties suffer.

Molten aluminium is poured from a ladle into the die. Gravity draws it through the running system and into the cavity. Sand cores can be set into the die before pouring to create internal features, undercuts, or hollow sections that the die alone could not produce.

After solidification and a controlled cooling period, the die is opened, the casting extracted, and the running system removed. The casting then moves to inspection and, where required, post-process operations.

Advantages of Gravity Die Casting

Superior surface finish: the steel die produces a smoother surface than sand, reducing finishing time
Improved mechanical properties: faster solidification produces a finer grain structure and higher tensile strength
Dimensional consistency: permanent tooling delivers repeatable accuracy across a production run
Reduced porosity: lower gas content compared to sand, important for pressure-tight applications
Sand cores: complex internal geometry is achievable within a die casting, combining the benefits of both processes

Gravity Die vs Sand Casting: Choosing the Right Process

The choice between the two processes depends on the component, the volume, and the requirements. Gravity die casting offers better surface finish and mechanical properties, but the tooling cost is higher and the process is better suited to aluminium than to iron or copper-based alloys.

At Maybrey we offer both processes from the same facility, which means we can advise on the right approach for each application without any bias towards one process over another.

Gravity Die Casting at Maybrey

Our gravity die casting operation produces aluminium castings to 25 kg in a full range of alloys, from commercial grades through class one aerospace-specification aluminium. All dies are designed in-house by our engineering team. We cast the die blocks themselves in our iron sand foundry, giving us control over material quality and lead times from the start.

Many gravity die castings leave our facility fully machined and heat-treated, reducing your supply chain to a single point of contact. For aerospace and defence work, our die casting operation is certified to AS9100 Rev D, with unbroken aerospace approval since 1937.

Explore our Gravity Die Casting capability

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Bespoke Architectural Castings

gabi.huiam.net — Mon, 06 Nov 2023 14:48:21 +0000

Maybrey Precision Castings has been producing ironwork and non-ferrous castings for the built environment for more than 177 years. Our architectural work takes us from the restoration of listed heritage buildings to new-build public realm projects, and from ornamental ironwork to precision structural components.

The range of what architects, heritage specialists, and public authorities ask us to produce is deliberately wide. We have cast replica lampposts for Regent's Park with no original drawings to work from, decorative ironwork for some of the most visited public buildings in the country, and art commissions for international public spaces. What connects these projects is the same requirement: accuracy, quality, and respect for the original.

Where Our Castings Stand

We have had the privilege of producing castings for some of the most significant buildings and public spaces in the UK, including:

Houses of Parliament
The National Gallery
The Victoria and Albert Museum
The British Museum
St Pancras Station
The War Office
Regent's Park (Crown Estate Paving Commission)
Westminster Council

[Sam to confirm: V&A and British Museum to be verified for public reference before publication.]

Our work has also travelled further: art castings for installations in Central Park, New York, and commissions delivered to Antigua, Switzerland, Germany, and the Netherlands.

What We Produce for Architecture

Heritage ironwork: railings, gates, balusters, bollards, lamp post components, grates, and bespoke fittings
Bronze and copper work: door furniture, plaques, decorative panels, and signage
Restoration pieces: matching or replacing missing or damaged historic ironwork from drawings, samples, or photographs
New architectural commissions: bespoke work for new-build projects with heritage character

Working Without Drawings

Heritage restoration often means working with incomplete information. Original drawings rarely survive. We are experienced in reverse engineering from a physical sample, using 3D scanning to produce a CAD model and spectrometric analysis to identify the original metal.

This capability was central to our recent project producing SG iron lampposts for the Outer Circle of Regent's Park: no original patterns, CAD models, or technical drawings existed. We 3D scanned an original lamppost, removed decades of paint and wear from the scan data, and produced new tooling from the resulting model.

Read the full case study: SG Iron Lampposts for Regent's Park

Explore our Architectural & Heritage services

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