MACHINING
Machining Services & Pattern-Making at Boro Foundry
We are specialists in large-capacity machining and precision pattern-making, providing milling and turning for larger dimensional components. Our comprehensive machine shop utilises advanced 3-axis CNC machinery to manufacture complex components from a wide range of materials.
Extensive Machining Capabilities
Our extensive machining capacity allows us to fulfil a wide range of customer requirements. We can machine a wide range of free issue materials including plate, fabrications, flame cut profiles and castings. The in-house machine shop also compliments our foundry to deliver an end-to-end solution.
In-House Breakdown & Component Repair Services
Through our machining facility, we offer comprehensive breakdown services, enabling us to manufacture replacement components entirely in-house from an existing broken or worn-out component to a finished product.
ISO Certified Machining & Quality Assurance
We have held ISO certification since 2010, and our fully skilled machining operators are committed to maintaining the highest standards of inspection and quality control.
Machining Capabilities Overview
Component sizes up to 10 metres
Tolerances down to ±0.01 mm
CNC & manual machining in-house
One-off, small batch & production runs
Aluminium, steel, stainless, cast iron & Ni-Resist
City & Guilds trained machinists (30–40+ years’ experience)
Machining Equipment & Capacity
Boro Foundry operates a diverse range of CNC and manual machining equipment designed to support complex castings, large fabrications, and precision-critical components across one-off, small batch, and production work. Our in-house machining capability allows us to control quality, lead times, and tolerances while handling a wide variety of materials, sizes, and component geometries.
From large travelling column bedmills capable of machining castings up to 10 metres in length, through to high-accuracy horizontal machining centres and vertical turning capacity, our machine shop is configured to match the real-world demands of heavy industry, energy, and infrastructure projects.
Below is an overview of our core machining assets and their on-site capabilities.
Butler Elgamill HE4000 – CNC Travelling Column Bedmill
The Butler Elgamill HE4000 is a CNC travelling column bedmill that underpins Boro Foundry’s large-format machining capability.
Designed for rigidity and stability, it is used when component size, mass and complexity demand controlled, predictable cutting performance. Its extended travel allows large castings and fabrications to be machined in a single setup, reducing handling and improving dimensional consistency.
The machine is routinely used for drilling, milling and boring operations on oversized components across one-off and small batch work.
| Feature | Specification |
|---|---|
| Machine type | CNC travelling column bedmill |
| X / Y / Z travel | 8200 × 1250 × 1765 mm |
| Maximum workpiece | 10,000 × 1250 × 1500 mm |
| Spindle speed | 2250 RPM |
| Taper | BT50 |
| Surface finishes | 1.6 – 3.2 µm |
| Accuracy | ±0.025 mm |
| Materials | Aluminium, steel, stainless steel, cast iron |
| Control | Heidenhain 426 |
| Programming | On and offline |
| Typical work | Large fabrications, complex castings |
| Operator experience | City & Guilds trained, 30+ years |
Soraluce SLP8000 – CNC Travelling Column Bedmill
The Soraluce SLP8000 is a CNC travelling column bedmill that expands Boro Foundry’s capacity for large, complex machining work. With higher spindle speeds and an integrated tool magazine, it supports efficient multi-operation machining without compromising accuracy or surface finish.
The machine is well suited to large castings and fabrications that require multiple milling, drilling and boring operations within a single machining cycle.
It is typically used for one-off and small batch components where flexibility, repeatability and controlled tolerances are essential.
| Feature | Specification |
|---|---|
| Machine type | CNC travelling column bedmill |
| X / Y / Z travel | 6500 × 1600 × 1000 mm |
| Maximum workpiece | 8000 × 1000 × 1500 mm |
| Spindle speed | 3000 RPM |
| Taper | BT50 |
| Tool magazine | 40 tools |
| Surface finishes | 1.6 – 3.2 µm |
| Accuracy | ±0.025 mm |
| Materials | Aluminium, steel, stainless steel, cast iron |
| Control | Heidenhain 430 |
| Programming | On and offline |
| Typical work | Large fabrications, complex castings |
| Operator experience | ONC trained, 25+ years |
Correa A30/30 – CNC Fixed Bedmill
The Correa A30/30 is a CNC fixed bedmill used for machining medium-sized castings and fabricated components. Its fixed-bed design provides a stable machining platform, making it well suited to heavier parts where rigidity and consistency are important.
The machine is commonly used for drilling, milling and boring operations on components that require reliable dimensional control.
It supports one-off and small batch work across a range of industrial applications, balancing flexibility with dependable machining performance.
| Feature | Specification |
|---|---|
| Machine type | CNC fixed bedmill |
| X / Y / Z travel | 3000 × 1200 × 1200 mm |
| Maximum workpiece | 3000 × 1200 × 1000 mm |
| Spindle speed | 2500 RPM |
| Taper | BT50 |
| Surface finishes | 1.6 – 3.2 µm |
| Accuracy | ±0.025 mm |
| Materials | Aluminium, steel, stainless steel, cast iron |
| Control | Heidenhain 426 |
| Programming | On and offline |
| Typical work | Medium fabrications, medium castings |
| Operator experience | City & Guilds trained, 30+ years |
Mazak Horizontal Centre Nexus 6000 II – CNC Horizontal Machining Centre
The Mazak Horizontal Centre Nexus 6000 II is a CNC horizontal machining centre used for high-accuracy and repeatable machining work. Its horizontal configuration and large tool magazine support efficient multi-face machining with minimal manual intervention.
The machine is particularly suited to batch production where consistency, close tolerances and surface finish are critical.
It is commonly used for repeat and consumable components in demanding industrial applications, including the waste-to-energy sector.
| Feature | Specification |
|---|---|
| Machine type | CNC horizontal machining centre |
| X / Y / Z travel | 800 × 800 × 800 mm |
| Maximum workpiece | 900 × 800 × 800 mm |
| Spindle speed | 7000 RPM |
| Taper | DIN 69871 |
| Tool magazine | 80 tools |
| Surface finishes | 0.8 – 1.2 µm |
| Accuracy | ±0.01 mm |
| Materials | Steel, stainless steel, cast iron, Ni-Resist |
| Control | Mazatrol |
| Programming | On and offline |
| Typical work | Batch components, waste-to-energy consumables |
| Operator experience | City & Guilds trained, 30+ years |
Bridgeport Series II Interact 4 – CNC Bedmill
The Bridgeport Series II Interact 4 is a CNC bedmill used for flexible jobbing and small batch machining work. Its compact working envelope makes it well suited to varied component types and fast turnaround requirements.
The machine is commonly used for milling and drilling operations where versatility and operator control are important.
It supports low-volume production and ad-hoc machining tasks alongside Boro Foundry’s larger CNC capacity.
| Feature | Specification |
|---|---|
| Machine type | CNC bedmill |
| X / Y / Z travel | 750 × 350 × 145 mm |
| Maximum workpiece | 750 × 350 × 120 mm |
| Spindle speed | 3000 RPM |
| Taper | ISO 40 |
| Surface finishes | 1.6 – 3.2 µm |
| Accuracy | ±0.05 mm |
| Materials | Steel, stainless steel, cast iron |
| Control | Heidenhain 151 |
| Programming | On machine |
| Typical work | Jobbing work, small batch machining |
| Operator experience | City & Guilds trained, 30+ years |
XYZ SLX555 – CNC Lathe
The XYZ SLX555 is a CNC lathe used for turning operations on one-off and small batch components. Its flexible control system allows parts to be machined efficiently while retaining a high level of operator control.
The machine is suitable for a wide range of turning work across steel, stainless steel and cast iron components.
It is regularly used where adaptability and straightforward setup are required, particularly for non-repetitive or varied work.
| Feature | Specification |
|---|---|
| Machine type | CNC lathe |
| Swing over bed | 660 mm |
| Swing over saddle | 370 mm |
| Spindle speed | 30 – 1800 RPM |
| Surface finishes | 0.8 – 1.6 µm |
| Accuracy | ±0.03 mm |
| Materials | Steel, stainless steel, cast iron |
| Control | ProtoTRAK |
| Programming | On machine |
| Typical work | General turning operations |
| Operator experience | City & Guilds trained, 30+ years |
Webster Bennett 60” DH – Manual Vertical Borer
The Webster Bennett 60” DH is a manual vertical borer used for large-diameter turning operations. Its robust construction allows heavy cuts to be taken with stability and control on substantial components.
The machine is particularly suited to vertically oriented parts where size, weight and access make horizontal turning impractical.
It is typically used for one-off and small batch work on large castings requiring reliable, controlled material removal.
| Feature | Specification |
|---|---|
| Machine type | Manual vertical borer |
| Maximum diameter | 2000 mm |
| Maximum height | 700 mm |
| Spindle speed | 3.8 – 83 RPM |
| Surface finishes | 0.8 – 1.6 µm |
| Accuracy | ±0.03 mm |
| Materials | Steel, stainless steel, cast iron |
| Control | Manual |
| Typical work | Vertical turning, large components |
| Operator experience | City & Guilds trained, 40+ years |
FREQUENTLY ASKED QUESTIONS
Do you machine castings in-house?
Yes — Boro Foundry offers both CNC and manual machining in-house. This allows us to deliver castings as fully finished components, reducing handling time and improving quality.
What materials can you machine?
We machine castings in grey iron, SG iron, carbon steel, stainless steel, Ni-Hard, Ni-Resist and other high-performance alloys.
Can you supply finished, inspected parts?
Absolutely. We offer full machining, dimensional inspection and documentation. Components are delivered ready for installation or assembly.
Do you machine to BS or ASTM standards?
Yes. We can produce and inspect components to BS, ASTM, DIN or customer-specific specifications, with full traceability.
