SERVICES

Pattern Types & Applications

Aerox Engineering manufactures the full range of pattern types required by modern foundries — from simple single-piece patterns to complex match plate and core box assemblies.

Foundry Pattern Manufacturing

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The full range of patterns engineered to specific casting processes and production volumes.

Match Plate Patterns

Cope and drag patterns mounted on a precision-machined aluminium or cast iron plate for high-speed automated moulding lines. Engineered to DISA, HWS, and BMD moulding machine standards.

HIGH VOLUME

Split pattern assemblies for medium and large castings, with precision-located dowel systems and hardened wear inserts. Suitable for green sand, no-bake, and CO₂ moulding processes.

MEDIUM / LARGE

Cope & Drag Patterns

Single-piece and segmented loose patterns for prototype, low-volume, and large one-off castings. Manufactured with correct shrinkage allowances and draft geometry.

Loose Patterns

PROTOTYPE

Shell core, cold-box, and hand-ram core boxes for internal cavity formation. Engineered with precise core print geometry, vent provisions, and ejector systems.

Core Boxes

INTERNAL CAVITY

automotive

Gated Pattern Assemblies

Fully integrated runner, gate, and riser systems machined into the pattern assembly. Designed using casting methoding principles to optimise fill velocity and minimise turbulence.

NO DRAWINGS NEEDED

Reverse Engineered Patterns

Patterns reconstructed from worn originals, physical castings, or obsolete tooling using industrial 3D scanning and CAD reconstruction. Output is a fully dimensioned, foundry-ready pattern.

Tool & Die, Fixture & Jig Patterns

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Beyond foundry patterns — precision tooling for downstream manufacturing operations.

Match Plate Patterns

Precision-machined die patterns and tool bodies for press tools, forming dies, and stamping tooling. Engineered to tight dimensional tolerances with hardened insert provisions.

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Machining Fixtures

Custom machining fixtures to hold castings and components securely during VMC machining. Ensures repeatability, reduces setup time, and eliminates positional error across production batches.

Drilling jigs, assembly jigs, and inspection jigs manufactured to drawing or reverse engineered from existing tooling. Used across automotive, defence, and heavy engineering operations.

Jig Patterns

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Composite & Epoxy Tooling

Epoxy tooling board and composite pattern construction for lightweight, dimensionally stable tooling — including low-volume production patterns, check fixtures, and prototype tooling.

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Premium Engineering Services

Advanced services for customers with critical, complex, or time-sensitive requirements.

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Casting Simulation Support

Pattern geometry and methoding reviewed against casting simulation outputs — ensuring the tooling is optimised for fill, solidification, and yield before the first heat is poured.

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Tight-Tolerance Pattern Certification

For critical applications, patterns are fully dimensionally certified with documented inspection reports — providing traceability from tooling to casting.

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Rapid Turnaround

Dedicated capacity allocation for breakdown and urgent replacement patterns — minimising foundry downtime when legacy tooling fails or is lost.