When you’re searching for an aluminium casting partner, it usually means one thing: you need a reliable, cost‑effective solution that performs flawlessly in the real world. Whether you’re fighting tight deadlines, wrestling with part complexity, or looking for a supplier who actually understands design-for-manufacture, Hallam Castings is a name you can trust.
We help design teams transform early concepts into production‑ready components through high‑pressure aluminium diecasting engineered for manufacturability, repeatability, and value.
Why Design for Manufacturing (DFM) Matters
The decisions made at the design stage are responsible for up to 70% of total part cost. A well‑designed diecast part doesn’t just look good—it also:
– Reduces cycle times
– Improves tool life
– Eliminates unnecessary finishing processes
– Prevents costly redesigns & tooling modifications
– Accelerates your path to mass production
Our specialist engineers collaborate with your design teams to refine your concepts early, ensuring every feature is optimised for high‑pressure die casting performance—without compromising function.
Our comprehensive range of services
Hallam provides high-volume CNC machining for a wide variety of industry sectors with production requirements ranging from die-cast aluminium components to complex assemblies. The company also offers guidance in the selection of materials or development of bespoke alloys and finishing treatments for optimum product functionality and performance.
Hallam provides cast aluminium components, finished products and manufacturing expertise to more than 40 UK and European OEMS, including household names such as Bisley, NIDEC and D W Windsor. Hallam also manufactures leading-edge Hi-Fi and PA systems, urban space lighting and urban activity control system housings, assembling complex machined and powder coated aluminium die castings with a wide range of other manufactured components for improved, long-lasting performance. Hallam works closely with research organisations such as the Advanced Manufacturing Research Centre, University of Sheffield to remain at the forefront of new developments in manufacturing and materials science.
About us
Hallam’s pressure casting unit has 8 high-performance German Frech machines capable of creating aluminium castings weighing up to 8 kg. The company also has six state-of-the-art CNC machining centres for precision machining, toolmaking and prototyping. In addition Hallam has a fully automatic in-house powder coating unit and offers design support and prototyping facilities using state-of-the-art IT and manufacturing systems.
Hallam manufactures and tests, including mechanical property testing, prototypes of new components or products based on designs created using Solidworks Professional CAD software. Prototyping facilities include CNC machining using CAMWORKS for CAD files transfer; 3D printing in a variety of materials including metals; and bespoke fabrications for feasibility testing. Prototypes encompass a wide variety of customer specifications and concepts ranging from garden products to complex electronic equipment.
