Grey and Ductile Cast Iron Components Engineered and Manufactured to your Specifications. Quality Castings. Manufactured in the UK

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1 Grey and Ductile Cast Iron Components Engineered and Manufactured to your Specifications Quality Castings Manufactured in the UK

2 Reliable, Cost- Reliable, cost-effective, UK based manufacturing At Thomas Dudley, we understand the need for organisations to work with trusted suppliers. As such, we provide a reliable, cost-effective, UK based source of manufacture for high quality grey and ductile iron castings. We have been manufacturing castings since 1920 and call upon unrivalled expertise to engineer bespoke solutions for customers representing most industry sectors. Outstanding service Our success has been built upon a unique ability to deliver an outstanding service by working with customers throughout each project. We can also provide the complete engineering, design and development service or alternatively, simply use your existing patterns. In addition, we can choose from 6 automated moulding lines including a new Disamatic facility and airset capabilities to provide the perfect production platform. Assured quality Thomas Dudley offers assured product quality. We manufacture in the UK and are a quality accredited organisation. Best practice methodologies are employed throughout our foundry and are underpinned by stringent quality procedures and Six Sigma. Our Advanced Thermal Analysis System (ATAS) enables us to carefully monitor and control melt quality to consistently ensure the integrity of our grey and ductile iron. Rigorous post production testing is also undertaken. 2 To request a quotation or meeting to discuss your casting requirements

3 Effective Security of supply Thomas Dudley offers an extremely secure source of supply from our Black Country foundry in the heart of the West Midlands. Employing around 400 people and generating revenues exceeding 30 million, the Thomas Dudley Group is established, successful and financially robust. When customers choose to work with us therefore, they do so with the assurance of knowing they have selected a manufacturing partner who will support them long into the future. We also invest heavily in technology and as such, are able to continually improve, adapt and evolve with the businesses of every customer. Cost-effective casting solutions Thomas Dudley has the expertise to engineer the complete competitive, value for money solution. In addition to selecting the most cost-effective method of manufacture, we call upon extensive on site logistical capabilities to produce components in large volumes and store them on behalf of customers. Proactively stock controlling these components, we can then deliver in smaller batches, allowing customers to free up cash flow and allocate other valuable resources elsewhere in their businesses. A unique quality and customer driven foundry delivering proven manufacturing solutions: Manufacturing flexibility and the ability to deliver to extremely short lead times A one-stop-shop for grey and ductile iron castings to 120Kg from one-offs to large production batches 90 years experience and unrivalled expertise A reliable, stable and secure source of supply Full design and development including CAD/CAM and in-house pattern shop where required On-site warehousing and pro-active stock control where required Family owned business that reacts rapidly to customer requirements Continual investment in the very latest technology Quality assured, ethical and environmentally responsible Flexible nationwide delivery within 48 hours or better, outside standard working hours and even at weekends Proven track record call or foundrysales@thomasdudley.co.uk 3

4 Unrivalled An Unrivalled Service As you would expect from one of the UK s leading engineering foundries, Thomas Dudley provides the complete castings service. From initial brief to design, manufacture and delivery, we work closely in partnership with customers throughout each stage of a project. Design and development As a member of the highly successful Thomas Dudley Group, we are able to take advantage of resources, research, design and development capabilities that are simply beyond most other foundries. Thomas Dudley s team of technical specialists and design engineers can develop new casting designs or modify your own existing CAD files. Our fully integrated design and prototyping facilities include: CAD/CAM including SolidWorks modelling that is directly linked to CNC pattern making equipment In-house tool room, pattern shop and core making facilities In-house laboratory equipped with spectrometer, sand testing, metallographic and physical testing technology Manufacturing Our foundry operates six automated moulding lines including a new Disa production facility equipped with automatic pouring technology alongside air set moulding capabilities, all of which are supported by cupola and electric melting. This provides a unique ability to respond rapidly to customer requirements and manufacture high quality components in all grades of grey and ductile iron. We also have the ability to manufacture the most intricately shaped castings ranging from the size of a 50p piece up to 120Kg in weight as one offs or in large production batches. 4 To request a quotation or meeting to discuss your casting requirements

5 Finishing Once we have manufactured castings, a comprehensive range of finishing serviced can be provided. Castings can be supplied painted, coated, enamelled and in a range of specialist finishes. We can also deliver castings in bespoke packaging and produce sub assemblies by integrating castings with other existing components. Machining Our in-house machine shop can undertake precision drilling, automated grinding and machining whilst purpose built shot blasting equipment allows even thin section castings to be accurately prepared. Warehousing and stock control Our extensive warehousing facilities allow us to produce components in large batches and call off and deliver smaller quantities as and when they are required. This allows customers to take advantage of the most cost effective manufacturing batch sizes without tying up valuable resources in stockholding and storage. Delivery Based in the heart of the West Midlands, Thomas Dudley is perfectly positioned to deliver castings quickly to every part of the UK. In addition, our customer focussed transport strategy ensures that castings can be delivered nationwide within 48 hours of manufacture. Unlike less flexible suppliers, we can also deliver at weekends or outside standard working hours to suit any given requirement. call or foundrysales@thomasdudley.co.uk 5

6 Unparalleled Unparalleled Expertise Thomas Dudley s expertise in designing and manufacturing cast iron components is simply unparalleled. Over the years, we have engineered castings for customers in most industry sectors including: General engineering Catering Heating Marine Rail Oil Automotive Leisure and entertainment Construction Civil engineering Credentials and accreditations Family owned and managed business since 1920 Grey iron grades BS EN 1561:1997 Ductile iron grades BS EN 1563:1997 CAD/CAM and SolidWorks modelling CNC pattern making In-house pattern shop Fully equipped laboratory 6 automated moulding lines including a new Disamatic facility Air set moulding capabilities Full range of machining, finishing and packaging services Bespoke stock holding solutions Manufacturing in accordance with BS OHSAS 18001, BS EN ISO and BS EN ISO 9001 Best practice methodologies underpinned by Six Sigma Environmentally responsible production 6 To request a quotation or meeting to discuss your casting requirements

7 Endorsements Customer Endorsements When we needed to source bespoke cast iron railing stanchions for a major new build contract, Thomas Dudley provided the perfect solution. They worked with us to complete the project in eight weeks and the service they provided throughout was exceptional. Pudsey Diamond Engineering Limited. Although we needed to find a new less labour intensive method of production, it was essential to retain the original product characteristics. Thomas Dudley understood this and identified a design that could be easily moulded out of cast iron. We are delighted with the results of the project which has helped us keep pace with growing demand. Hotpod LLP. Our old process was both time consuming and expensive. We therefore decided to explore the possibility of producing our new gear shifters as an SG iron casting. We are delighted with our decision to work with Thomas Dudley. The new parts offer assured quality and have enabled us to achieve significant cost reductions with our machining costs being cut by around 75%. Thomas Dudley s support and engineering input have been invaluable. Forge Motorsport. call or foundrysales@thomasdudley.co.uk 7

8 We have attained BS EN ISO 14001, the recognised standard for environmental management systems We employ best practice and lean manufacturing principles throughout the organisation to maximise manufacturing efficiency We invest heavily in technology designed to reduce our emissions and energy consumption We manufacture in the UK and not overseas, helping to reduce the environmental cost and carbon footprint of transportation Our catalogues are printed on recycled paper by local printers We recycle our waste paper by shredding it on-site and re-use it for packing purposes Technical Specifications (EN and Previous National Standards): Minimum Tensile Strength Grey Cast Iron N/mm 2 Tonf/in 2 BS EN BS 1452 BS 1452 DIN 1691 NF ANSI/ASTM 1561: A32:101 A A EN-GJL GG-15 FGL A A A A A A Minimum Tensile Strength/Elongation % Spheroidal Graphite (Nodular or Ductile) Cast Iron N/mm 2 Tonf/in 2 BS EN BS 2789 BS 2789 DIN 1691 NF ANSI/ASTM 1561: A A EN-GJS /22 24/17 FGS /18 GGG /12 420/ / /7 500/ / / / / / / /2 Approximate equivalents only. E. & O.E. We reserve the right to alter or modify the specification without notice E. & O.E. CISCT