Metal Casting
Bring your design to life in cast metal.
We specialise in lead-free pewter casting, producing everything from intricate pin badges and jewellery findings to figures, medals, coins, belt buckles and keychains — cast, finished and polished entirely in our Kent factory.
Whether you need a single detailed prototype or thousands of identical pieces, our combination of traditional hand-pouring and modern centrifugal casting means we can match the process to your quantity, detail and budget.
What Is Metal Casting?
Metal casting is the process of pouring molten metal alloy into a mould to produce a precise, durable replica of a master design. We work almost exclusively in fine English lead-free pewter (tin alloy), a metal prized for its fine detail reproduction, weight, and traditional "silver-like" finish, without the toxicity concerns of old-fashioned pewter.
We process over 36 tonnes of pewter tin alloy per year, using a semi-automated centrifugal casting machine for volume production, alongside manual pouring machines reserved for smaller runs and highly intricate work that benefits from a hands-on touch.
Popular Uses for Cast Metal Items
Our casting process is used across a wide range of products and industries:
Pin badges & button badges
Medals, coins and tokens
Belt buckles and buttons
Jewellery and jewellery findings
Figurines and replica models
Bookmarks and crowns
Charms and keychains
Golf ball markers
Tooling components
This makes metal casting a natural fit for awards and recognition, heritage and museum ranges, corporate gifts, licensed merchandise, and personal accessories — anywhere a design needs to feel substantial, high-quality and long-lasting.
How We Do It
1. Master creation - your design is turned into a master casting, either from your supplied artwork/model or created by our in-house design team.
2. Mould making - the master is laid out on a silicone disc, then cured under heat and pressure in a vulcaniser to form a production mould.
3. Casting - the mould is spun in our centrifugal caster while molten pewter is poured into the centre, filling every detail of the design. For smaller or more intricate runs, this is done by hand on our manual pouring machines.
5. Fettling & finishing - every piece is fettled and rumbled to remove sharp edges and imperfections, then polished in a light detergent solution and dried.
6. Final finish - items can be highly polished to a bright silver-like shine, hand-antiqued to highlight fine detail, or plated in gold or other metals.
Footage from our factory in Folkestone, Kent
Frequently Asked Questions
What is lead-free pewter?
Lead-free pewter is a modern tin-based alloy that gives the traditional silver-grey pewter look and fine detail reproduction, without the lead content used in historic pewter. It's food-safe and suitable for jewellery and items with prolonged skin contact.
What's the maximum size for a cast item?
We cast up to approximately 6 inches (15cm). For larger items, get in touch as we may be able to advise on alternative processes or multi-part construction.
What finishes are available?
Highly polished gives a silver-like effect, hand-antiqued (to bring out fine detail in recessed areas), or plated in silver, gold, or other finishes to match your brand or brief.
Can you help if I only have a rough idea, not a finished design?
Yes. A large proportion of our work starts as a brief, sketch or concept. Our design team will work with you to develop it into a production-ready master.
How long does mould-making and casting take?
Timescales depend on design complexity and quantity. Contact us with your brief for an accurate lead time.
Looking for a Complete Product, Not Just the Casting?
We can combine metal casting with our other in-house processes such as enamelling, embellishing and engraving to deliver a finished, packaged and ready-to-ship product, not just a raw casting.