Design Engineering and Manufacturing Solutions (DEMS) is Best Cast’s one-stop service, covering the selection of design methods, materials, manufacturing processes and quality controls used to design, develop and manufacture engineered components.
Our strength lies in delivering high-quality products at competitive prices. We use a range of software tools to develop and test components to customer specifications, and offer end-to-end support from design and rapid prototyping through to the manufacture of finished parts.
We work with a network of approved suppliers to support quality and turnaround times. We collaborate closely with customers and suppliers to find the most efficient way to manufacture each component, starting from part specifications, material properties, production volumes and budget. Combined with disciplined project management, this brings technical competence and reliability to every project.

Tool design and development is central to our die casting process. The quality of every casting depends on the accuracy and reliability of our tools, especially our dies and moulds. The process covers identifying the need for a new tool or an improvement to an existing one, designing and prototyping it, testing and evaluating its performance, and then building it for production.
Our designers, engineers and project managers simulate each tool’s performance under different conditions to identify issues such as interference, stress concentration and wear before the tool is built. The team stays involved at every stage, making design refinements that improve performance and lower cost.
At Best Cast, we design feeding systems that support sound castings and minimise project delays, and we use data analytics to maintain consistent quality across our finished parts.

Shell core making forms a thin shell of resin-coated sand inside a heated metal core box. The finished core is placed in the die, and when molten metal is poured, it forms the internal cavities and passages of the casting.
Best Cast specialises in shell core making and produces complex cores for small and large castings across a wide range of applications and industries. We have in-house expertise in shell core processes and in shell core box design.

Best Cast has in-house heat treatment for aluminium castings, including solution treatment and artificial ageing (T6 condition). Most of our castings are used in the as-cast condition, but we also serve applications that need higher mechanical properties or properties different from the as-cast material. Heat treatment changes the properties of the cast alloy by taking the casting through a controlled thermal cycle or series of cycles.
Our furnaces are designed for uniform heating across every part of the load. Drop-quench furnaces allow rapid quenching, and their fan and duct layouts keep the temperature uniform throughout the chamber and the parts.
Strict quality controls are applied at every stage of our heat treatment process.

Best Cast offers a range of finishing operations that improve the surface finish, dimensional accuracy, appearance, performance and durability of castings. The processes used for each part depend on the required properties and application of the final component.