Project Overview

Blackwood Engineering is a specialist supplier of counterbalance weights to major manufacturers worldwide. While their team regularly works with foundries to deliver high-quality cast components, much of this production is handled overseas.

To strengthen their internal expertise and improve collaboration with casting partners, Blackwood approached Boro Foundry to deliver a tailored training programme for their Project Engineering team.

The Challenge

Blackwood’s engineers were experienced in specifying and sourcing cast components, but like many organisations working with external foundries, they had limited hands-on exposure to how castings are actually produced.

This created a gap between design intent and manufacturing reality.

Without a practical understanding of foundry processes:

  • Communication with suppliers could become more complex than necessary
  • Project timelines were sometimes extended due to avoidable back-and-forth
  • Engineers lacked full visibility of the constraints and considerations involved in casting production

Blackwood recognised that strengthening this knowledge would not only improve internal capability, but also lead to more efficient and effective collaboration with their foundry partners.

The Solution

Boro Foundry worked closely with Blackwood to design and deliver a bespoke training programme, tailored specifically to the needs and experience levels of their engineering team.

Drawing on over 65 years of casting expertise, the programme was built to provide both theoretical understanding and practical, hands-on experience of the sand casting process.

Training Delivery

The training was carefully structured around real-world applications relevant to Blackwood’s work.

Using historical examples of counterbalance weights, Boro was able to anchor discussions in familiar components, allowing engineers to connect directly with the challenges and considerations they encounter in their day-to-day roles.

The session was led by Boro’s Sales Director, Sam Edwards, whose experience spans nearly two decades across multiple areas of foundry operations — from shop floor to commercial delivery — bringing a depth of practical insight to the training.

Classroom Learning

The day began with a structured session covering the fundamentals of sand casting, including mould preparation, pattern design, gating systems, and the variables that influence casting quality.

By working through real examples, engineers were able to explore common challenges and discuss practical solutions in an open, collaborative environment.

Hands-On Casting Experience

Following the classroom session, the team moved into the foundry for a practical exercise.

Using a 3D printed pattern of a real component, participants were guided through the full moulding process, including:

  • Mould preparation
  • Core placement
  • Cutting ingates
  • Closing the mould ready for casting

This hands-on element allowed engineers to physically engage with the process, reinforcing the concepts covered earlier in the day.

Factory Tour

The training concluded with a tour of Boro’s manufacturing facility, giving the team a complete view of how individual processes come together within a live production environment.

The Outcome

The training provided Blackwood’s engineering team with a significantly deeper understanding of the casting process, from initial design considerations through to final production.

As a result:

  • Engineers are better equipped to communicate with foundry partners
  • Design and specification decisions can be made with greater confidence
  • Collaboration with suppliers is more efficient and aligned

The session received very positive feedback, with interest in extending similar training opportunities to other members of the organisation.

The Key Takeaway

For companies sourcing cast components, a strong understanding of manufacturing processes is often the difference between a smooth, efficient project and one that becomes unnecessarily complex.

By investing in practical foundry knowledge, Blackwood has strengthened its ability to deliver high-performance engineered solutions, while building more effective relationships with its supply chain.

This case study highlights the value of combining engineering expertise with real-world manufacturing insight — something Boro Foundry continues to support through both production and knowledge-sharing partnerships.

Looking to Strengthen Your Casting Knowledge?

Whether you’re designing components, sourcing castings, or managing supplier relationships, a deeper understanding of foundry processes can unlock significant efficiencies.

Get in touch with Boro Foundry to discuss tailored training or collaborative support for your next project.