A Sheffield manufacturer is installing one of the world’s largest commercially operated vacuum arc remelting furnaces as part of an £18m investment in advanced UK casting capability.

Castings Technology has lifted the multi-million-pound VAR furnace into position at its new 196,000 sq ft factory in Sheffield, ahead of the site becoming operational later this year.

The furnace is the largest of its type in commercial use in the UK and one of the largest in the world. It will be used to produce high-integrity titanium alloy castings for mission-critical applications across the aerospace, energy and industrial sectors.

Using the latest vacuum arc remelting technology, the furnace melts material from a titanium electrode at precise weights and temperatures. The molten metal is then poured into a ceramic mould and spun, using centrifugal force to fill the mould under controlled pressure.

The process enables Castings Technology to manufacture components with thinner and more precise wall sections than can be achieved using static casting methods alone.

The furnace was developed in collaboration with its supplier and also incorporates an automated loading system. Parts and moulds are transported on a bogie rather than being loaded manually or by forklift truck, improving safety and streamlining production.

It forms part of a wider programme of advanced manufacturing investment at the new Sheffield facility. The factory will also house a vacuum heat treatment furnace, described as one of the largest in Europe, alongside the latest CNC machining and 3D printing technology.

Castings Technology says the investment will increase capacity and productivity while securing critical elements of its supply chain.

The company already produces some of the largest titanium castings in the world and is expanding as demand grows from aerospace and other industries for titanium components combining high strength-to-weight ratios with resistance to corrosion and heat.

The project is creating 20 jobs directly at Castings Technology, as well as further employment within its regional supply chain. Recruitment this summer has included maintenance engineers, pattern shop operatives and welding apprentices, alongside roles across production, quality, technical and commercial functions.

Richard Cook, managing director of Castings Technology, said: “This is a significant moment for Castings Technology. The new furnace represents a major step forward in our manufacturing capability and reflects the scale of our ambition as we move into our new home in Sheffield.”