CAPABILITIES
Aluminium Die Casting
High Integrity Aluminium Die Casting’s
Founded in 1894, Lupton & Place has built a reputation as one of the UK’s leading aluminium casting specialists. Now part of BCW Group, we combine more than 130 years of foundry expertise with advanced manufacturing technologies and vertically integrated capabilities. Producing over 5 million castings annually, we deliver high performance aluminium casting solutions engineered for quality, consistency and long term customer success.
DiecASTING Specialist
Complete Casting Solutions
Through Lupton & Place, BCW Group delivers a comprehensive aluminium casting capability designed to support customers throughout the entire product lifecycle. From gravity and pressure die casting through to machining, surface treatment, assembly and inspection, every process is engineered to maximise quality, efficiency and supply chain reliability.
Our continued investment in people, technology and automation enables us to manufacture everything from complex structural castings to high-volume production components. Backed by over a century of foundry expertise and the wider capabilities of BCW Group, we provide customers with a single manufacturing partner capable of supporting projects from initial concept through to finished component delivery.
How We Do It
Delivering Complete Aluminium Casting Solutions
Our aluminium casting operations combine engineering expertise, advanced process control and modern foundry technology to produce components that meet demanding performance requirements. Working closely with customers throughout development and production, we optimise designs, material selection and manufacturing methods to achieve the ideal balance of quality, performance and cost efficiency.
This collaborative approach enables us to support everything from specialist, low volume components through to large scale production programmes. By partnering with customers at every stage of the process, we deliver reliable, high quality aluminium castings tailored to the specific demands of each application.
Structural Die Casting
Advanced Structural Casting Capability
Lupton & Place was the first UK foundry to install the Bühler CARAT 130 structural die-casting machine, strengthening our ability to manufacture large, complex aluminium components. The 1300-tonne toggle-free system combines real-time closed-loop process control, automated dosing and robotic extraction to support the production of high-integrity structural castings where dimensional stability, consistency and mechanical performance are critical.
Structural Casting Capability
- Bühler CARAT 130 Structural Die-Casting Technology
- 1300 Tonne Locking Force Capability
- Toggle Free Machine Design
- Real Time Closed Loop Process Control
- Westomat Dosing Furnace Integration
- Wollin Automated Die-Spray Technology
- ABB Robotic Casting Extraction
Gravity Die Casting
Gravity die casting uses the natural force of gravity to fill permanent moulds, producing aluminium components with excellent mechanical properties, durability and low porosity.
This manufacturing method is particularly suited to medium and high-volume applications where strength, dimensional accuracy and long-term performance are essential. Modern tilt-gravity technology ensures controlled metal flow and consistent manufacturing outcomes.
Gravity Die Casting Benefits
- Excellent Mechanical Properties
- Low Porosity Aluminium Castings
- Wide Alloy Capability
- Complex Internal Features using Sand Cores
- Medium & High Volume Production
- Excellent Dimensional Consistency
Pressure Die Casting
Pressure die casting enables the rapid production of lightweight, highly accurate aluminium components through the controlled injection of molten metal into precision engineered dies.
Supported by advanced Bühler real time closed loop control systems, the process delivers exceptional repeatability, complex geometries and cost-effective production for high-volume manufacturing programmes.
Pressure Die Casting Benefits
- High Volume Production Capability
- Excellent Dimensional Accuracy
- Thin Wall Component Manufacture
- Complex Geometries and Designs
- Reduced Cost per Component
- High Strength Aluminium Castings
Die Casting Tooling Design & Simulation
Getting the tooling right is fundamental to achieving consistent, high-quality die castings while reducing development risk and production costs.
Before any tooling is manufactured, we use advanced casting simulation software including MAGMASOFT and Castflow to design and optimise runner, gating and overflow systems. This enables our engineers to evaluate metal flow, identify potential issues and support Design for Manufacture (DFM) activities before production begins.
The same simulation technology can also be applied to existing tooling modifications, allowing proposed changes to be tested virtually before committing to physical alterations.
Gravity Die Casting Benefits
- Reduced Development Risk
- Optimised Runner, Gating & Overflow Design
- Improved Casting Quality & Consistency
- Design for Manufacture (DFM) Support
- Reduced Tooling Changes & Trial Iterations
- Right First Time Production Processes
Benefits to the Customer
Over a Century of Foundry Expertise
Supporting customers with proven casting knowledge and manufacturing experience.
Multiple Casting Technologies
Gravity, pressure and structural die-casting solutions from a single supplier.
Integrated Manufacturing Capability
Access to machining, finishing, fabrication, assembly and inspection through BCW Group.
Flexible Production Volumes
Supporting specialist projects through to large-scale manufacturing programmes.
Reliable Quality & Traceability
Controlled manufacturing processes supported by rigorous validation and inspection.
VerSATILE engineering services
Industries We Support
BCW’s precision manufacturing expertise supports OEMs and Tier 1 suppliers across:
Aerospace
Automotive
Defence
Off Highway
Quality you can trust
Verified Through Rigorous Certification Standards
Our machining and inspection processes are certified to globally recognised standards.
Advanced Engineering Solutions
Facility
Our Precision Components Manufacturing operations span BCW’s Burnley and Wellingborough facilities, with over 300,000 sq. ft. of production space dedicated to CNC machining, automation, and precision inspection.
Each site operates under a unified quality system, ensuring repeatable standards across all programmes.
Key facility highlights include:
- Over 90 CNC machining centres, including multi-axis vertical and horizontal platforms
- Automated machining cells for high-volume continuous production
- Dedicated sliding head cell for small, complex parts
- Large component machining area with high-torque horizontal spindles
- Advanced metrology suite featuring CMM, FARO, laser trackers, and surface finish testing
As a new customer to BCW we are very happy with the support we have received. The manufacturing support has enabled us to identify and implement a more cost efficient and streamline manufacturing process on material we had in stock. They are now storing and machining this material with their treatments division anodising the product to give us a one stop solution. We have a future desire to look at BCW to provide our material and give us a full turnkey solution.
The defence sector demands nothing less than excellence, and BCW has proven to be a trusted partner by delivering high-quality parts on time, every time. Their engineering expertise and unwavering focus on standards give us the confidence that our systems are built on trust and durability.”
Daniel Bates
Project Buyer Expert Technologies Group
We have consistently experienced outstanding service and quality from BCW. Their timely delivery, attention to detail, and responsive communication have made them a trusted partner in our operations. We highly recommend them for reliable and professional supply solutions.
Daniel Simpson
Buyer Lotus Group
I have worked with BCW via various companies, for nearly 15 years on products ranging from machined castings, to extrusions, through to anodising of components within the automotive and aerospace sectors. BCW have a vast array of technical and manufacturing knowledge to help customers overcome any potential manufacturing hurdles that might arise. With modern manufacturing equipment, and impressive finishing facilities, they are a great option for any customer looking for a top tier supply partner on any programme. It has been a pleasure to work with the company, and I look forward to working with them for many more years to come, as they really are one of the UKs best.
David Hayden
Senior Buyers Lotus Group
BCW are a new supplier to us and have made an excellent first impression. They have demonstrated a proactive approach, prompt responsiveness, and a friendly manner throughout our interactions. The pricing received to date has been highly competitive, and we look forward to building and maintaining a strong working relationship with them in the future.
Leah Pennington
Sales Administrator Haworth Castings
In our recent work with BCW’s Coatings and Treatments division, Columbia Staver has experienced a high level of responsiveness, strong technical capability, and careful attention to detail. We value their professional and supportive approach.
Anthony Sethill
Managing Director Columbia Staver
Let’s Engineer Success Together
Whether you’re developing new technology, scaling production, or strengthening your supply chain, BCW’s vertically integrated approach delivers precision, performance, and partnership at every stage.
Speak to one of our specialists