Fine precision sand casting

Sand casting frequently asked questions

What is precision sand casting?

Precision sand casting is a manufacturing process used to produce complex aluminium components by pouring molten aluminium into a highly accurate sand mould. The process enables the creation of intricate geometries while maintaining excellent structural integrity and consistent repeatability. At Maycast Nokes, precision sand casting is used for both prototype and production components, with rigorous quality control measures implemented throughout the manufacturing process.

What lead times can you offer?

Every component is unique. Lead-times are dependent on many factors, such as production capacity, pattern/tooling design and manufacture, post processing operations, finishing, sub-contract availability and the complexity of each part.

Component lead-time is calculated by taking all of these inputs into account, and can be separated into two stages: Tooling (Initial) Lead Time and Production Lead Time.

What tolerances can you achieve?

There is a complete table of sand casting tolerances in the Quality section – this includes linear dimensions, wall thickness and surface finish.

Do you offer machining and finishing?

Yes – Alongside producing high‑quality aluminium castings, we also offer full machining and finishing — giving you a complete, production-ready component from a single supplier.

However, one important factor in this process is machinability: how easily a material can be cut and shaped to achieve an accurate part.

While aluminium is generally very machinable, different alloys behave differently. Some machine quickly and cleanly, while others require slower cutting speeds or more robust tooling. That’s why alloy selection plays a key role in achieving the best machining performance, lead times, and final surface quality.

By managing the complete process, from casting to machining, we help you choose the right alloy from the start, ensuring efficiency, consistency, and a high‑quality finished part.

How do you inspect casting quality?

Quality assurance is integral to every stage of our operation. We utilise advanced inspection technology, including CNC coordinate measurement systems and laser profile scanning, to maintain precise manufacturing standards. We hold both ISO 9001:2015 & AS9100, along with NADCAP, a globally recognised, industry-managed accreditation system for the aviation, defence, and space sectors.

Our fully integrated production and management systems allow us to deliver efficient, reliable solutions that support both lean manufacturing practices and customer-specific quality requirements.

What materials do you offer and how do I select the most appropriate one for my application?

We predominantly produce castings in aluminium alloys; however, we also regularly manufacture investment castings in stainless steel and other steel alloys. Material selection is largely determined by the required physical and mechanical properties, together with the inherent casting characteristics of each alloy.

Research is key, we provide several downloads on this website that inform the decision-making process. We encourage you to contact us to discuss your application in detail, enabling us to fully understand your requirements and recommend the most suitable solution.