Precision investment casting, superalloys and forgings for aerospace, gas turbines and transportation
Doncasters Group Ltd
Leeds (UK, HQ) · Bochum (DE) · Breckerfeld (DE) · Chard (UK) · Droitwich (UK) · Sheffield-Killamarsh (UK) · Ryde (UK) · Springfield, MA (US) · Groton, CT (US) · Oxford, AL (US) · Long Beach, CANew on Amplifa
Manufacturing expertise since 1778
Doncasters is an international manufacturer of superalloys and precision cast components headquartered in Leeds (UK) with more than 3,000 employees at 14 production sites in six countries. The company produces complex investment castings using the lost-wax process, including vacuum casting in single-crystal (SX), directionally solidified (DS) and equiaxed (EQ) technology, as well as vacuum-melted alloy barstock and mastermelt alloys on nickel, cobalt and iron base. The value chain extends from alloy production via wax pattern and ceramic core manufacture, casting, heat treatment and hot isostatic pressing through to CNC machining, grinding and non-destructive testing. Customers include OEMs from aerospace, industrial gas turbines, transportation, energy and medical technology, including Siemens, GE, Rolls-Royce and Safran. Founded in 1778 in Sheffield, the company has invested over USD 170 million in capacity expansion, modernization and quality since 2020.
- Site
- LS1 5AB Leeds
- Processes
- Precision investment casting in equiaxed technology for nickel and cobalt alloys,, Vacuum investment casting single crystal (SX), directionally solidified (DS) and conventionally cast, Investment casting of IGT blades and vanes (equiaxed), vacuum casting, complex, Stud welding systems, fixed-mounted manual and automatic feed systems as well as, Production and supply of vacuum- and air-melted iron, nickel and, Investment casting of precision castings incl. turbine wheels with 3D-printed wax pattern process, Closed die forgings, forging design,, Large precision structural investment castings, vacuum investment casting of nickel and
- Materials
- Nickel-base superalloys, Cobalt-base superalloys, IN 713C, IN 713LC, GMR235, IN 738LC, MAR M 246, MAR M 247
- Certificates
- EN9100/AS9100 Rev D (site-specific), ISO 9001:2015 (site-specific), ISO 14001:2015 (site-specific), IATF 16949 (Uni-Pol/Trucast), ISO 13485 (Chard), ISO 50001:2018 (Bochum), ISO 45001 (site-specific), NADCAP (NDT, Heat Treatment, Welding – site-specific), ISO 17025 (UKAS, Ross & Catherall), VDA 6.3 A-Rating (Uni-Pol), ISO 9001, EN 9100 / AS9100, ISO 14001, ISO 45001, ISO 13485, ISO 50001, IATF 16949, NADCAP, ISO 17025 (UKAS)
- Founded
- 1778
- Employees
- > 3,000 (worldwide,
- Industries
- Aerospace, Defense, Industrial gas turbines, Transportation/Commercial vehicles, Energy/Oil & Gas, Medical technology
- 01
Mastermelt and alloy production in vacuum induction melting (VIM) incl.
- 02
Wax pattern and ceramic core manufacture, also via 3D printing
- 03
Ceramic shell building and vacuum or air-melt investment casting (EQ, DS, SX)
- 04
Heat treatment and hot isostatic pressing (HIP)
- 05
CNC machining and precision grinding
- 06
Non-destructive testing (X-ray, FPI/MPI, CMM) and release
Materials and processes
Nickel-base superalloys
Used in vacuum investment casting for blades, rotor blades and hot-gas-path components of aero and industrial gas turbines.
Cobalt-base superalloys
For structural castings and hot-gas-path components with high temperature requirements.
IN 713C
Nickel-base alloy for cast turbocharger turbine wheels in the transportation sector.
IN 738LC
For high-stress investment castings in turbomachinery.
MAR M 247
For directionally solidified and equiaxed cast components in hot-gas positions.
GMR235
Nickel-base alloy for turbine wheels of turbochargers and microturbines.
Titanium
Forged at Doncasters Forgings of Springfield for flight-critical structural and engine components.
High-temperature-resistant stainless steel
Used in die-forged parts for energy and industrial applications.
Iron-base superalloys
Vacuum- and air-melted bar material for the investment casting industry.
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Precision investment casting in equiaxed technology for nickel and cobalt alloys,Casting | – | 300 mm (blade and vane airfoils) | 40 kg (vacuum melt casting capacity), 35 | – | Nickel-base superalloys, Cobalt-base superalloys, exotic alloys, conventional materials |
| Vacuum investment casting single crystal (SX), directionally solidified (DS) and conventionally castCasting | – | 880 mm (DS casting) | 42 kg (DS), 30 kg (SX), 20 kg (EQ); | – | Nickel-base superalloys, Cobalt-base superalloys |
| Investment casting of IGT blades and vanes (equiaxed), vacuum casting, complexCasting | – | 870 mm (vane segments) | 47 kg (solid and profiled blades), | – | Nickel-base superalloys, Cobalt-base superalloys |
| Stud welding systems, fixed-mounted manual and automatic feed systems as well asJoining | – | – | – | – | – |
| Production and supply of vacuum- and air-melted iron, nickel andCasting | – | – | 500 kg (VIM melt) – 7200 kg (VIM melt), 1000 or 2000 | – | Nickel-base superalloys, Cobalt-base superalloys, iron alloys |
| Investment casting of precision castings incl. turbine wheels with 3D-printed wax pattern processCasting | – | – | 3 kg (product weight), diameter up to | 2.5 million components per year | 713C, 713LC, GMR235, 738LC, MAR M 246, MAR M 247, nickel-base alloys |
| Closed die forgings, forging design,Forming | – | 558 mm (22 in) | 0.1 lb (56.6 g) – 50 lb (22.68 kg) | – | titanium, high-temperature-resistant stainless steel, nickel-base special alloys |
| Large precision structural investment castings, vacuum investment casting of nickel andCasting | – | 1143 mm (45 in diameter) × 762 mm (30 in) | 454 kg (1000 lb pouring weight vacuum) | – | Nickel-base superalloys, Cobalt-base superalloys |
| Vacuum and air-melt investment casting in nickel and cobalt-base superalloys,Casting | – | 600 mm (24 in) | 72.57 kg (vacuum melt), 74.84 kg | – | Nickel-base superalloys, Cobalt-base superalloys |
| Production of high-performance vacuum-refined superalloys (mastermelt) from variousCasting | – | – | 9 kg (ingot weight) – 250 kg (ingot weight), 10000 kg | – | nickel-base alloys, cobalt-base alloys, iron-base alloys |
| Production of high-performance nickel-base 'hot-end' turbocharger turbine wheels, rapidCasting | – | – | 0.04 kg – 2 kg, diameter up to 160 mm | 1.5 million wheels per year | 713C, 713LC, GMR235, MAR M 246, MAR M 247, nickel-base alloys |
| Vacuum precision investment casting, CNC machining, precision grinding, heat treatment,Casting | – | 130 mm (part diameter) | 31 g – 4000 g | – | superalloys, nickel-base alloys |
| Post-cast services: X-ray inspection, finishing and repair welding, CMM,Testing | – | – | – | – | – |
14 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Programmable hydraulic hammers | – | – | Up to 4535 kg (10000 lb) blow weight | – | Doncasters Forgings of Springfield, MA, USA |
| Drop hammer | – | – | Weight 5443 kg (12000 lb) | – | Doncasters Forgings of Springfield, MA, USA |
| Vacuum induction melting furnace (VIM) | – | – | Pouring weight 500–7200 kg | – | Ross & Catherall, UK |
| Vacuum induction melting furnace (VIM) | – | – | Melting capacity 250–10000 kg | – | Doncasters Superalloys of Long Beach, CA, USA |
| Wire EDM (electrical discharge machining with wire) | – | – | – | – | Doncasters Superalloys of Long Beach, CA, USA |
| Ingot grinding machine | – | – | Ingot diameter 41–178 mm | – | Doncasters Superalloys of Long Beach, CA, USA |
| 3D GOM scanner | GOM | – | – | – | Trucast, USA (Newberry, SC) |
| 3D wax pattern printing system (additive/rapid prototyping) | – | – | – | – | Trucast, USA (Newberry, SC) |
| 3D wax pattern printing system | – | – | – | – | Trucast, UK (Ryde, Isle of Wight) |
| CNC surface grinding and turning machines | – | – | Part size Φ30–130 mm | – | Uni-Pol, Mexico (Mexicali) |
| CNC vertical milling machines | – | – | Part size Φ30–130 mm | – | Uni-Pol, Mexico (Mexicali) |
| Vacuum casting system | – | – | Pouring weight up to 270 kg (Deritend); up to 40 kg (Chard); up to 454 kg (Groton); up to 72.57 kg | – | Multiple sites (Deritend UK, Chard UK, Groton CT USA, Oxford AL USA) |
| Steam hammers | – | – | Up to a weight of 5 tonnes | – | Penistone Road Forge, Sheffield, UK (historical, 1898) |
| Crucible furnaces | – | 3 | – | 1865 (hist | Doncaster Street, Sheffield, UK |
Additional services
Reference customers
Quality and certifications
The sites are accredited on a site-specific basis, among others, to ISO 9001, EN/AS 9100, ISO 14001, ISO 45001, IATF 16949 and ISO 13485; NADCAP approvals are held for non-destructive testing, heat treatment and welding. The testing equipment portfolio includes X-ray, FPI/MPI, CMM, laser and blue-light measurement, 3D GOM scanning as well as a UKAS-accredited chemical analysis laboratory (ISO 17025).
| Evidence | Chard | Bochum | Droitwich (Deritend) | Sheffield (Ross & Catherall) | Ryde (Trucast UK) |
|---|---|---|---|---|---|
| ISO 9001 | |||||
| EN 9100 / AS9100 | |||||
| ISO 14001 | |||||
| ISO 45001 | |||||
| ISO 13485 | |||||
| ISO 50001 | |||||
| IATF 16949 | |||||
| NADCAP | |||||
| ISO 17025 (UKAS) |
History
- 1778
Daniel Doncaster founds the company in Sheffield (file manufacturing); trademark granted by King George III.
- 1863
Renamed 'Daniel Doncaster & Sons'.
- 1902
Registered limited company; expansion into die forging.
- 1972
Ross & Catherall begins producing vacuum-melted barstock.
- 2005
Founding of Jiangyin Uni-Pol Ltd in China.
- 2020
Change of ownership and management-led turnaround program; over USD 170 million invested since then.
- 2026
Agreed sale of IVOSTUD to the DUBAG Group (Lenbach Equity Opportunities III); announcement of a new USD 50 million plant in Auburn, Alabama.