Design & Development

Design & Development


The design & development of castings can be a complex web of suitable radius, draft angles, undercuts, heavy sections and many more unforeseen issues. Commonly known as the “draftsman’s dreams” not every casting is as simple as may be first thought – our expertise in design, manufacturing and methoding is the key reason why here at Charles H Coward Ltd you are in safe hands.

Using our vast experience of casting knowledge hand in hand with the latest Solidworks CAD technology we can help with the design of the parts to give you the product you desire, in a casting friendly design.

From here we can use both CAD and experience to predict and confirm the metal flow analysis to ensure the casting will cast as we expect and hopefully eradicate any potential production issues we may encounter – other options at this stage is to produce dimensional reports, show true metal thicknesses and where we can potentially improve the design yet further.

Once the analysis has been done it’s time to give you a realistic image of how the casting will look and perform – we do this using our Solidworks Visualise package. This can give you a real life image of the part for use prior to manufacture – we have seen these images used to promote the products, sell the idea but more importantly bring to life the original idea.

Finally the files that we can produce form this modelling work are used in the manufacturing of the tooling, whether that be imported into the CNC cutting of wood or die tooling or to create working dimensional drawings for our traditional pattern makers to work form – this form of technical drawing can also produce machining drawings where required.

CHC Sheffield

From design to delivery Charles H Coward Ltd will be with you every step of the way. Click here to find out more on how we can help with your design and development projects.

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Rapid Prototyping

Rapid Prototyping


Moving on from the design and development stages we can then take your projects to that next step with working cast prototypes giving you the ability to get hands on and see the idea become reality.

The prototype castings we produce are also suitable to be used to prove a concept, ensure dimensional accuracy and give you a physical fitting solution for fitting parts.

Using new age methods such as 3D printing and CNC cutting techniques we can create model tooling suitable for prototyping – then with our traditional green sand moulding skills we can create mould from this tooling ready for the casting production in ferrous or non-ferrous materials.

We joking call this our “dinosaurs and droids” process as it uses the latest in 3D CAD & CAM printing technologies hand in hand with one of the oldest forms of sand cast moulding.

We have seen great success with our prototyping service over the years – with customers seeing a reduction in initial set up costs and also avoiding the requirement for expensive tooling modifications later down the line meaning that the process is extremely cost effective for you the customer.

We can also work with your budgets on design and prototyping projects with the option to recover the costs involved in this process back against the final tooling charges once the project becomes live with ourselves, for more information on this please contact one of our sales team.

CHC Sheffield

Our “dinosaurs & droids” process takes the latest in 3D printing technologies hand in hand with traditional moulding skills to achieve practical cast working samples for customers trials and approval.

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Patterns & Tooling

Patterns & Tooling


Sand Cast Tooling

Sand Cast tooling can be manufactured in various ways, whether it be simple wooden model pattern equipment for small batch or complex production or multiple impression patterns in frames for regular production we have it covered.

All our sand cast tooling is manufactured using sustainably sourced woods, high quality resins and is the most economical of tooling options.

Gravity Die Cast Tooling

CAD design is once again used for the production of single or multiple impression gravity die tooling that we manufacture, materials such as cast iron or steel are used to form the permanent moulds and this is then machined and assembled to produce the working tooling.

We aim to keep all our gravity die tooling manually operated with the aid of rack and pinion opening and closing systems however where required we can introduce varying degrees of automation depending on production rates required.

Pressure Die Cast Tooling

High pressure die tooling is manufactured using tool steel that has been treated to provide the hardness and durability that is required in the automated casting process. Once again the tooling can be single or multi impression.

Dies can also be manufactured as standalone units or a system that is known as a bolster system, this is where a main framework of the tooling is manufactured to house smaller inserts plates, and so instead of manufacturing numerous full tools we only produce the one main tool housing and a number of bolster plates. This can be extremely cost effective if you require a number of similar sized components.

Our pressure die tooling is externally sauced and manufactured by trusted tooling partners who we have a long working relationship with and who know how we and our equipment work.

CHC Sheffield

Produced both in-house and externally by trusted suppliers, all our CNC and traditional tooling and patterns are produced using the finest quality sustainable materials available.

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Assured Quality

Assured Quality


The QMS in place here at Charles H Coward Ltd is the BS EN ISO 9001:2015 and is an internationally recognised quality management system, which encompasses all aspects of the business from the initial receipt of the enquiry through to the final check, despatch and delivery of products

The standards are split down into the main areas of the management system with each area of the business being controlled by its own set of operating procedures. These procedures are subject to constant scheduled internal audits as well as undergoing external audits from an internationally accredited organisation.

All areas of the QMS is analysed internally and the results are published internally throughout the business to allow us to monitor the continued effectiveness of the system and to ensure that continued improvement and customer satisfaction is achieved.

In addition to the requirements detailed in the ISO we have internal quality standards for products that we constantly monitor and improvements are implements where required.

In October 2019 the company was rewarded for its hard work and dedication to quality by winning the Barnsley & Rotherham Chamber of Commerce award for Excellence in Manufacturing – the judging panel commented that the result was down to the quality policies in place at the company as well as showing consistent business improvement and advancing with modern technologies.

Click the button to view copies of our ISO 9001:2015 Certification and our Internal QMS.

CHC Sheffield

Charles H Coward Ltd – a name you can trust – Winners of the 2019 Barnsley and Rotherham Excellence in Manufacturing award.

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Downloads

Downloads


Please feel free to download our certification and brochures. If you require more information or assistance, please visit the Get In Touch page for details on how to contact us.


BS EN ISO 9001:2015 Certificate


C. H. Coward – Terms of Sale


C. H. Coward – Quality Management System


Staveley Cast Products – Company Brochure


Conservatory Cast Systems – Company Brochure


Blast Parts Media – Product Brochure

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© Copyright 1948 - C.H. Coward Limited.

540 Ecclesfield Road, Sheffield, S5 0DJ

Company number 00456385

VAT GB 172 41 8077

      

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