Precision aluminium castings - cost-effective and premium-quality

MAHLE Powertrain provides unmatched casting experience underpinned by over 30 years of extensive development, high skill levels and service to our customers. The benefits of a casting process originally engineered to produce high performance parts for demanding race engine applications was quickly established as being equally relevant for road engines and other applications. New OE customers for niche and series castings were soon seeing the advantages of using our products.

As such, our foundry in Worcester has a long and proven history of supplying cost-effective, premium-quality castings for many clients across a broad spectrum of applications.

The casting process is equally suitable for prototype phases and series production parts in a range of volumes. Make-like-production methodology minimises process and product variations between phases and can also help optimise validation requirements and the associated costs.

Unsurprisingly, both automotive and non-automotive clients recognise the benefits of our well-established casting process, achieving high standards of quality, weight optimisation, design flexibility and machining cost savings all of which have become highly relevant for their applications in today’s evermore challenging manufacturing and customer sensitive environment.

Demanding and high-dependency applications such as cylinder blocks, heads, cam covers, pump bodies, brake callipers and aerospace components are core products for our foundry and our casting experience has successfully demonstrated its advantages in all these applications.
Our product portfolio is extensive and not least includes the famed V12 block and cylinder head castings produced since 1996 for Aston Martin vehicles.

MAHLE’s pioneering I-3 downsizing engine incorporates castings that have been developed and produced in our foundry. These engines have been subjected to rigorous development testing at extreme loads and internal pressure levels over hundreds of hours, with zero casting failures which is testament to the integrity and durability inherent in our products.

Enhanced casting processes, design flexibility, precision and product integrity combine to satisfy the different needs of design and development engineers, buyers, machinists and quality engineers alike and these attributes are equally applicable whether in low-volume production of prototypes and development components or for higher-volume series production.

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Worcester Foundry	Cylinder Heads