Investment Casting in the UK Railway Industry

The railway industry has long been an integral part of Britain's transport network, dating back to 1825. Now, in 2025, exactly 200 years later, modern commuters are rightfully demanding more efficient, safe, and sustainable railways and as such, the manufacturing processes for key components have had to evolve. At Dean Group, we have demonstrated that investment casting is a reliable method that continues to innovate, and we take pride in contributing to future technological advancements in the rail sector.

Current Railway Projects in the UK

HS2: High Speed 2

As one of the UK's most ambitious infrastructure projects, HS2 is setting new standards in rail travel. Investment casting has proven its flexibility in producing components for the UK's first high-speed rail network, allowing for lightweight yet robust designs, which differs from the methods used in other countries such as Japan for its bullet train.

In Japan, components must be designed to withstand earthquakes; in contrast, the UK does not face this seismic risk, allowing its investment casting to focus on performance under different environmental conditions, such as possible flooding and storms. This adaptability and options of rapid prototyping to test certain parts of a design enable the UK to innovate and develop components through 3D printing for casting, such as brake system housings and coupler components tailored to its specific transport needs.

The precision of investment casting ensures these parts meet the stringent performance and safety requirements for trains travelling at over 200mph. Additionally, investment casting allows for lightweight yet robust designs, contributing to energy efficiency and reduced wear on critical systems—key priorities for a project of this scale.

Network Rail's Track Renewal Programme

Network Rail's ongoing track renewal initiatives aim to modernise the ageing infrastructure across the UK, including dated rail fasteners, baseplates, and joint assemblies. At Dean Group, we have the ability to cast these parts with consistent quality and precise tolerances to ensure longer track durability, which reduces maintenance frequency. This not only helps minimise operational disruptions but also helps with the railway company's broader corporate goals of cost efficiency and reliability, which help to prevent frustrated commuters.

Rail Improvements for the North

Manchester Oxford Road train station is set to undergo significant improvements aimed at enhancing the passenger experience. Originally built in 1849, the station has seen increased traffic due to the current investment boom in Manchester. This surge in new residents and students is seeing many more commuters use this station, putting strain on platform elements such as edges and support brackets. Through investment casting, these elements can be replaced and upgraded to ensure safety and longevity whilst also allowing for innovative new designs for a futureproof station that blends its historic features with modern innovations.

The new station design will facilitate efficient drainage and maintenance, supporting sustainability and leading to improved services for passengers. These enhancements will ensure that Manchester Oxford Road train station remains a vital hub for travellers in the years to come.

Advanced Materials in Railway Casting

The UK's railway sector is also reaping the benefits of advanced materials made possible through investment casting.

Nickel-Based Superalloys

Nickel-based superalloys, with their excellent resistance to high temperatures and mechanical stress, are used for components in trains, such as turbine blades in diesel engines, due to their ability to withstand extreme conditions, ensuring the longer service life of trains on the network and improved performance.

Lightweight Aluminium Alloys

For non-load-bearing components, lightweight aluminium alloys are gaining traction in areas such as interior fittings of train carriages and auxiliary equipment as they help to reduce the overall weight of rolling stock. These alloys contribute to greater energy efficiency, enhanced speed, and lower operational costs—an increasingly important focus as the industry prioritises sustainability.

Innovative Casting Techniques in the UK

We are always looking for advancements in manufacturing techniques that can further enhance utility for investment casting, specifically for railway applications.

3D-Printed Casting Patterns

Additive manufacturing is revolutionising traditional casting processes. UK manufacturers are increasingly employing 3D-printed patterns for investment casting, which enables rapid prototyping and unparalleled design flexibility. This technique allows complex geometries to be realised with reduced lead times, making it easier to refine designs and meet project-specific requirements.

Sustainability Initiatives

As the railway industry embraces greener practices, UK foundries like ours are championing energy-efficient casting methods and exploring the use of recycled materials in production. These efforts align with the broader sustainability goals of the UK whilst also reducing the industry's environmental impact.

Contact Dean Group for Railway Castings

Investment casting is undeniably a cornerstone of the UK's railway industry, offering unparalleled precision, durability, and adaptability to meet the demands of modern infrastructure projects. From HS2 to Network Rail's renewal programmes, and with innovations in materials and techniques, investment casting continues to drive advancements in performance and efficiency.

As the industry looks to the future, embracing digitalisation and sustainable practices, investment casting will remain an essential tool in shaping the UK's railways for generations to come. Contact Dean Group today, and our team will be on hand to assist in any railway casting needs.