Lestercast Ltd
Size
SME
Direct employees
40
Turnover (reported)
£7,800,000
Regional Markets
Asia, Australia, Europe, North America
Nuclear Contracting Tiers
Tier 5: Processors & Fabricators
Tier 4: Sub-component Suppliers/Distributors

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Accreditations

  • ISO 9001
  • ISO 9001:2015
  • TS 16949

F4N Case Studies

Lestercast Ltd

Castings

Major UK manufacturer of precision investment castings, offering bespoke components in a range of metals including high temperature and specialist alloys, for both industrial and commercial applications, supplying to a diverse and global market. Castings are used in every sector and in many different manners.

Overview

Lestercast are an award-winning, major UK manufacturer of Precision Investment Castings, offering bespoke components in a range of metals and specialist alloys, for both industrial and commercial applications, supplying to diverse and global markets through various methods of advanced manufacturing technologies.

The supply of precision investment cast components or products in a variety of metals, alloys and other specialist material with additional treatments and finishes applied to meet individual customer specifications enables any design to be turned into a prototype and finished metal casting; specifically complex metal shapes that are impossible to make through other methods.

With the range of materials and processes available, we can offer flexibility and versatility in component design and production to ensure that specifications are achieved and products meet the highest possible quality standards.

Metals that can be cast within our facilities include but are not limited to:-
+ Non-Ferrous Metals
+ Ferrous Metals
+ Carbon Steels
+ Stainless Steels
+ Aluminium
+ Brass
+ Bronze
+ Copper
+ Zinc
+ Superalloys
+ Inconel
+ Hastelloy
+ Nickel
+ Low-Alloy Steels

Founded in 1972, Lestercast has grown significantly, investing regularly in all aspects of the business to diversify its reach.

The firm produces parts up to 20kg from it's investment casting centre in Leicester as well as high-volume parts of up to 150kg through a longstanding, successful partnership foundry in China.

With it's own in-house R&D centre capable of corrosion testing and further rapid prototyping facilities, Lestercast invests heavily in continually strengthening development in services such as additive manufacturing, 3D modelling, rapid prototyping, the full investment casting process, precision casting and beyond.

Service and Specialities Lestercast Offer:-
+ Robotic Linishing
+ Spectrometer
+ Corrosion Testing
+ High-resolution wax 3D Printers / Projet Printers - High quality castings without the need for tooling
+ Stockholding
+ Thin wall castings
+ High temperature alloys
+ Heat treatment
+ Hipping
+ Non-destructive testing, Crack Detection and X-ray
+ Tensile Testing & Charpy Testing
+ Machining / CNC Machining
+ Controlled traceability
+ Strict 100% inspection for all China-made parts
+ CMM
+ Milling
+ Grinding
+ Wire Eroding
+ Rapid low-volume production
+ Chemical Blacking
+ Polishing (Mirror or Satin)
+ Anodizing
+ Patination
+ Powder Coating
+ Plating
+ Electro-polishing

Already working into the Nuclear industry, the knowledge of the stringent protocol required for the Nuclear sector is fully understood and adhered to.

Lestercast is also working with Castings Technology International, one of the Nuclear AMRC's sister centres - to develop techniques to further develop techniques to improve the surface quality of complex castings by replacing the traditional wax pattern with an additively-manufactured resin form.

Products and Services

Product Sector
Valves & Actuators - Standard Industrial Nuclear Civil
Valves & Actuators - Coded Standards Nuclear Civil
Tooling - General Engineering Nuclear Civil
Pumps - Standard Industrial Nuclear Civil
Pumps - Coded Standards Nuclear Civil
Fasteners and Bolting - Standard Nuclear Civil
Fasteners and Bolting - High Integrity Nuclear Civil
Cable Supports, Support Systems & Trunking Nuclear Civil
Condition Monitoring Equipment, Components & Systems Nuclear Civil
Consumables - Personnel Safety & Security Nuclear Civil
Detection Systems, incl Radiation, Neutron Source & Personnel Monitoring Nuclear Civil
Detectors, Measurement & Monitoring Equipment & Components, incl Airborne Contamination Nuclear Civil
Turbine Equipment, Systems & Components Nuclear Civil
Pressure Vessels, Heat exchanger & Tanks - Coded Standards Nuclear Civil
Mechanical Handling Lifting - Polar Crane Equipments & Systems Nuclear Civil
Instrumentation & Control Nuclear Civil
Fire Prevention & Safety Related Components & Systems Nuclear Civil
Filters & Filtration Equipment - Sea Water Cooling & Intake Systems Nuclear Civil
Forgings and Castings - General Engineering Nuclear Civil
Process Engineering Systems Nuclear Civil
Ferrous and Non ferrous Materials - Certified & Source Contolled Nuclear Civil
Ferrous and Non ferrous Materials - General Engineering Nuclear Civil
Forgings and Castings - Source Controlled Nuclear Civil

Due to the diversity of our business and the bespoke requirements of our customers, we manufacture components for most sectors including:-
Automotive, Motorsport, Oil & Gas, Electrical, Marine, Construction, Rail, Transport, Utilities, Nuclear, Power, Safety Systems, Valve, Pumps, Flow Measurement, Electrical Equipment/Sensors, High Temperature Applications, Architectural, Bronzes/Jewellery, Environmental, Aerospace, Agricultural, Alternative Energy & Renewables, Nuclear, Power Generation, Construction, Petrochemical, Subsea & Offshore, Utilities.

Site Facilities

Shop Floor

7000m2 Lestercast has been quoted to have 'The cleanest and most well-organised, modern foundry I've ever had the pleasure to visit'. In order to facilitate an efficient and effective environment and continue to improve productivity, Lestercast has a unique and unrivalled strategy in developing and maintaining a clean, well organised and streamlined foundry. We have implemented Lean Manufacturing systems throughout and, as part of this, we continually inspect and audit our facilities to ensure we maintain high standards in our manufacturing process, produce excellent quality components and achieve on-time delivery for our customers. Considerable investment has been made in new equipment, machinery and rapid prototyping technologies to support the diverse and constantly changing needs of the industries we support. We have also implemented a programme of major enhancements to our premises, in order to provide a pleasant, modern working environment for all of our employees, and to offer excellent on-site training and conferencing facilities. We are particularly proud of our facility and would encourage and welcome existing and prospective clients to visit us for a tour, refreshments and a chat!

Inspection / Testing

  • Clean room facilities
  • CMM machines
  • Non destructive testing - Magnetic Partical
  • Non destructive testing - Radiography
  • Non destructive testing - Ultrasonic
  • Pressure / Hydro Testing
  • Proof Load Testing
  • Temperature controlled facility for inspection

Recent Work

Non-Ferrous Metals - Aluminium Alloys, Zinc and Copper Based Alloys

Please find below the images of the breakdown of metals and alloys we offer in our casting procedures, we would be keen to discuss any other materials required. These tables are intended as a guide only, the full relevant standard specifications should be referred to when determining suitable materials for a particular product and its application.

Non-Ferrous Metals - Aluminium Alloys, Zinc and Copper Based Alloys

Ferrous Metals - Aluminium Alloys, Zinc and Copper Based Alloys

Please find below the images of the breakdown of metals and alloys we offer in our casting procedures, we would be keen to discuss any other materials required. These tables are intended as a guide only, the full relevant standard specifications should be referred to when determining suitable materials for a particular product and its application.

Ferrous Metals - Aluminium Alloys, Zinc and Copper Based Alloys

Ferrous Metals - Alloy Steels, Nickel and Cobalt Alloys

Please find below the images of the breakdown of metals and alloys we offer in our casting procedures, we would be keen to discuss any other materials required. These tables are intended as a guide only, the full relevant standard specifications should be referred to when determining suitable materials for a particular product and its application.

Ferrous Metals - Alloy Steels, Nickel and Cobalt Alloys