Casting Simulation Services

Casting simulation provides an accurate picture of the physical processes during mold filling, solidification, and cooling. The accuracy of the result depends primarily on the quality of the input data and how closely the simulation model matches the actual production process.

Accuracy depends on:

• Quality and completeness of the casting process parameters
• Accuracy of the casting, gating system, risers, mold, and core geometry
• Correct alloy and mold material properties
• Pouring temperature, mold temperature, and filling conditions
• Correct boundary conditions and heat-transfer parameters

Casting simulation can find defects and risks tied to mold filling, solidification, and casting deformation.

Solidification defects:

• Shrinkage porosity
• Shrinkage cavities
• Microporosity risk
• Hot spots
• Insufficient feeding

Filling defects:

• Misruns and incomplete filling
• Cold shuts
• High flow velocities and turbulence
• Mold erosion risk
• Trapped air risk
• Hydrostatic pressure distribution

Stress and deformation risks:

• Hot tears
• Cold cracks
• Residual stresses
• Warpage and dimensional distortion

No. Casting simulation cannot guarantee a completely defect-free part.

What simulation can do:

• Spot defect risks represented by the 3D model
• Show filling, temperature, and solidification behavior inside the mold
• Explain the physical reasons behind a production defect
• Compare different model revisions or process variants
• Reduce the number of changes you have to test directly in production

What simulation cannot control:

• Raw-material contamination or chemistry deviations
• Random production variations
• Equipment malfunctions
• Operator errors
• Improper mold assembly or handling
• Differences between the supplied parameters and actual factory conditions

To reproduce your casting process, we need the geometry and the available production parameters.

If some parameters are unavailable, tell us before the calculation. We will determine if we can use reasonable assumptions and clearly list them in the project plan.

Recommended formats:

• STEP (.stp, .step)
• IGES (.igs, .iges)

Also accepted:

• STL (.stl)
• Parasolid (.x_t)
• ACIS (.sat)
• SolidWorks native files

Standard processes:

• Sand casting
• Permanent mold / gravity casting
• Investment / lost-wax casting
• Lost foam casting

Processes evaluated individually:

• High Pressure Die Casting (HPDC)
• Low Pressure Die Casting (LPDC)
• Vacuum casting
• Centrifugal casting
• Continuous casting
• Other special casting processes

We offer two different service formats:

One-Off Casting Simulation

A single calculation for a specific 3D model and analysis plan. This service is best when you need an individual calculation without an ongoing optimization program.

PoligonSoft Engineering Partner

A 12-month engineering program for complex casting problems that require multiple model revisions and verification simulations. The program includes 2, 4, or 8 optimization Cases.

One-Off Casting Simulation:

Subsequent-calculation pricing applies to minor modifications (like updating the gating or feeding system) aimed at solving the same problem. A completely redesigned part requires a new First Calculation.

PoligonSoft Engineering Partner:

The real value of simulation depends on your tooling cost, production volume, defect rate, and how many physical trials you would otherwise need.

Simulation helps you:

• Check the casting process before cutting expensive tooling
• Compare technological changes before running production trials
• Cut down on unnecessary physical iterations
• Find high-risk areas before committing to production changes
• Make decisions based on calculated flow, thermal, and stress data

Yes. For a small production run, the main value comes from avoiding a single unnecessary tooling modification or a failed trial, rather than saving money on high-volume scrap.

Simulation is particularly useful for:

• High-value castings
• Complex geometries
• Prototype and pre-production validation
• Castings with expensive tooling
• Components where another physical trial would be costly or slow

The right option depends on how often your company needs calculations and who should control the work.

One-Off Casting Simulation

Best for a single calculation or occasional simulation tasks.

Engineering Partner

Best when you need ongoing engineering support and several verification simulations, but you do not want to operate the software internally.

PoligonSoft software license

Best when your company needs frequent simulations, immediate control over iterations, and an internal workflow without an annual Case limit.

A standard One-Off Casting Simulation typically takes 3 to 7 business days after we receive the project data and confirm the analysis plan.

The schedule may be longer when the project includes:

• Complex or incomplete geometry
• Missing production parameters
• Stress and deformation analysis
• A special casting process
• Additional model revisions

Engineering Partner projects are iterative. The timing for each Case depends on the calculation scope and how quickly your team prepares and submits updated models.

The exact delivery is defined in the project plan.

Depending on the selected package, the delivery may include:

• Technical report
• Defect-risk maps
• Filling sequence and flow-velocity results
• Temperature and solidification results
• Shrinkage and porosity criteria
• Stress and deformation results
• Videos and 3D visualizations
• Explanation of the physics behind the results

For an Engineering Partner Case, the results also include a comparison between the baseline and your model revisions.

Casting simulation uses physics-based modeling to reproduce the casting process virtually.

1. Model preparation

The supplied casting, gating system, risers, mold, and cores are prepared and converted into a finite-element model.

2. Material and process definition

The alloy, mold and core materials, temperatures, and other available parameters are assigned to the model.

3. Physics calculation

• Fluid-flow analysis: molten-metal filling, flow velocity, and turbulence
• Thermal analysis: heat transfer, cooling, and solidification
• Stress analysis: stresses, deformation, and cracking risk

4. Results analysis

The calculated fields and defect criteria are evaluated to find problem areas and explain the physics behind them.

5. Results delivery

The agreed visualizations, report, and engineering interpretation are delivered to your team.

No. Both One-Off Casting Simulation and Engineering Partner are performed by our engineers using our software and computing resources.

You provide the geometry, process data, and project goal. We run the simulation and deliver the results.

We work with both new castings and existing production problems.

For an existing production defect:

1. You provide the current model, process parameters, defect description, and inspection evidence.
2. We simulate your current process as the baseline.
3. We check if the baseline result matches the actual defect location.
4. We explain the physics and factors causing the defect.
5. Your engineers decide on the changes and update the CAD model or parameters.
6. We simulate the updated version and compare it with the baseline.

Yes. Customer models, process parameters, and simulation results are treated as strictly confidential.

NDA process:

1. Contact us before submitting sensitive project files.
2. We can provide our NDA template or sign your company’s NDA.
3. The NDA is signed before any confidential data is transferred.
4. Project files are then submitted for technical review.

Standard simulation services are done remotely.

• You submit the 3D model and process parameters electronically.
• We prepare and run the simulation remotely.
• Results are delivered electronically.
• Technical questions can be discussed by email or video call.

Solidification Only (€600)

Thermal and solidification analysis without calculating the mold-filling stage.

Finds: hot spots, solidification sequence, feeding effectiveness, shrinkage, and porosity risk.

Flow and Solidification (€740)

Includes calculated mold filling followed by thermal and solidification analysis.

Finds: everything in Solidification Only, plus filling sequence, flow velocity, turbulence, cold shuts, misruns, and other filling risks.

Full Cycle (€1,140)

Includes flow, solidification, stress, and deformation analysis.

Finds: everything in Flow and Solidification, plus residual stress, hot-tearing and cracking risk, warpage, and dimensional distortion.

We use simulation to track the physical behavior of your current gating system and compare it with your model revisions.

PoligonSoft can:

• Simulate the existing gating system
• Identify filling, velocity, turbulence, temperature, and feeding problems
• Explain the physics shown by the model
• Simulate updated CAD models supplied by your team
• Compare each revision with the baseline

Your engineers:

• Select the technological solution
• Update the gating system, casting model, or process parameters
• Decide which changes are practical for production
• Test and validate the changes in the foundry

We work with manufacturers producing metal castings across a wide range of industries.

Aerospace

• Turbine blades and structural components
• Thin-walled and complex castings
• Titanium and superalloy components

Automotive

• Engine blocks and cylinder heads
• Transmission housings
• Wheels and suspension components

Industrial machinery and energy

• Valves and pumps
• Mining and wear-resistant components
• Turbines and impellers

Jewelry and art casting

• Gold, platinum, and silver castings
• Thin details and filigree
• Bronze sculptures and art

Medical and precision components

• Orthopedic components
• Surgical instruments
• Precision cast parts

Common alloys: aluminum, steel, cast iron, superalloys, titanium, brass, bronze, and precious metals.

PoligonSoft Engineering Partner is a 12-month engineering program for teams with recurring casting problems that require multiple model revisions and verification runs.

You select a plan containing:

• 2 optimization Cases
• 4 optimization Cases
• 8 optimization Cases

All simulations are run by our engineering team. The program does not include a local software license.

A Case focuses on improving one casting to achieve a specific goal, like reducing shrinkage porosity, fixing filling issues, or lowering cracking risk.

One Case covers:

• One part
• One casting process
• One specific goal

The Case begins with a baseline simulation of the current process. It then covers the simulation and comparison of up to five model revisions.

1. Send Model and Process Data. You provide the 3D model, process parameters, defect description, location, and any photos or inspection results.
2. Reproduce the Problem. We simulate your current process to see if the software catches the real-world defect.
3. Explain the Physics. We analyze the simulation to explain the physical reasons and factors behind the defect.
4. Your Team Makes Changes. Your engineers decide on the changes and update the CAD model or process parameters.
5. Simulate and Compare. We run the simulation on the updated version and compare it with the baseline.
6. Repeat or Close the Case. The cycle ends when we hit the target result or after we evaluate five model revisions.

The baseline simulation is used to check if the supplied model and process parameters reproduce the problem you see in production.

If the baseline simulation does not reproduce the defect, the Case does not count against your annual total.

PoligonSoft investigates the physics.

• We run the simulations.
• We explain the physical mechanisms shown by the model.
• We identify the factors influencing the defect.
• We compare your model revisions with the baseline.

Your team selects and implements the changes.

• Your engineers select the technological solution.
• Your team updates the CAD model or process parameters.
• Your team determines which changes are practical in production.
• Your company tests and validates the changes on the foundry floor.

One Casting Optimization Case includes a baseline simulation and evaluation of up to five model revisions.

The Case closes when:

• We hit the target result; or
• Five model revisions have been evaluated.

The Case closes when either of these conditions happens first.

Contact us to discuss your casting projects, goals, and the most suitable Engineering Partner plan for your team.

After the initial discussion:

1. We confirm if the program fits your goals.
2. We define the details and the number of Cases.
3. We prepare a formal proposal.
4. The service agreement is signed.