Automating the Foundry: How Robotics Are Enhancing Efficiency

Driving real-world innovation in aluminium sand casting, we harness cutting-edge technology to tackle industry challenges worldwide. Our goal is clear: deliver faster, safer and more efficient foundry operations for our partners. By seamlessly integrating casting automation and advanced robotics, we elevate precision and repeatability and uphold the highest engineering standards – continuously striving for shorter lead times.

Advancing Foundry Automation With Robotics

Automation technology has revolutionised manufacturing, and foundries are no exception. By incorporating robotic solutions and 3D vision technology, we’ve fine-tuned our production processes to improve accuracy, speed and workplace safety. As our global presence continues to expand, we’re setting new standards in foundry automation and robotics-driven manufacturing, ensuring industries worldwide benefit from our expertise.

One of our latest milestones is the Vibro Decore Robot Loading Project, a state-of-the-art robotic system engineered to automate casting handling during the vibro decore process.

Inside the Vibro Decore Robot Loading Project

This advanced robotic cell streamlines our casting process, featuring the KUKA KR300 robotic arm, Roboception 3D vision technology and robust safety measures to ensure smooth and precise handling of castings.

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How the Vibro Decore Robot Loading System Works:

• The KUKA KR300 robotic arm, equipped with custom clamping grippers, handles materials with pinpoint accuracy.

• Roboception 3D vision technology ensures precise casting positioning, seamlessly transporting them from the supply lanes to the machine.

• Once the decore process is complete, the system efficiently moves finished castings onto an outgoing conveyor.

• Advanced safety features, including radar detection, light curtains and positional sensors, help protect our operators.

Installed in just three weeks, with production commencing in week 49 of 2024, the system has delivered immediate results. Our team quickly adapted, and the impact has been clear: higher efficiency, fewer manual errors and a safer working environment.

Innovation in Sand Removal & Efficiency Gains

Traditionally, removing sand from intricate castings required extensive time. While smaller moulds benefited from attritors, the growing size of our castings, particularly gigacastings, required a more efficient solution.

At our prototype facility, we've invested in a 3m x 2m shake-out deck designed to support up to six tonnes. While shakeout decks are not new technology, this has automated the sand removal process, cutting processing time by up to 80% and allowing us to increase the sand reclamation rate for reuse, boosting both efficiency and sustainability.

The Benefits of Robotics in Foundry Operations

Higher Productivity
With 24/7 casting automation in our niche volume series foundry, we’re able to meet tight production deadlines without compromising quality.

Improved Precision & Repeatability
Automation eliminates manual variability, ensuring every casting meets the highest quality standards.

Safer Workplaces
Reducing manual handling has significantly decreased the risk of workplace injuries.

Long-Term Cost Savings
While automation requires an initial investment, the long-term value is clear through efficiency gains and reduced error rates.

Data-Driven Optimisation
Real-time performance data allows us to improve processes continuously and drive greater efficiency.

A Smarter Future for Foundry Innovation

Innovation isn’t just about adopting new technology; it’s about finding smarter, safer and more efficient ways to deliver precision-engineered castings. Our investments in automation technology and robotics for foundries are helping us stay ahead in industries like automotive, motorsport, aerospace and beyond.

Looking forward, we remain committed to pushing the boundaries of what's possible in foundry technology. We’re eager to explore new advancements that will turn the impossible into reality.

Want to see these robotic innovations in action? Let’s talk about how we can bring efficiency and precision to your next project.