Expert Casting Simulation Services

Modern casting simulation software like PoligonSoft achieves 85-90% defect prediction accuracy when proper process parameters and material properties are provided. This accuracy has been validated against thousands of production castings across aerospace, automotive, and industrial applications.

Accuracy depends on:

• Quality and completeness of input data (material properties, temperatures, process parameters)
• Mesh resolution and quality of 3D model
• Correct boundary conditions and heat transfer coefficients
• Calibration against actual production data when available

Casting simulation can predict the following defects with high accuracy:

Solidification Defects:

• Shrinkage porosity
• Shrinkage cavities
• Microporosity
• Hot spots

Filling Defects:

• Misruns (incomplete fill)
• Cold shuts
• Turbulence & High velocities (Erosion risk)
• Hydrostatic pressure issues

Mechanical Defects:

• Hot tears
• Cold cracks
• Residual stresses
• Warpage & distortion

No, simulation cannot guarantee 100% defect-free castings, but it identifies approximately 90% of design-related potential issues before production, allowing you to make corrections early.

What simulation CAN do:

• Predict defects caused by design, gating, or feeding issues
• Identify thermal hot spots and cold spots
• Optimize process parameters to minimize defect probability
• Reduce scrap rates by 40-70% on average
• Eliminate need for 3-5 physical trial iterations

What simulation CANNOT prevent:

• Defects from contaminated raw materials
• Random process variations beyond normal parameters
• Equipment malfunctions or operator errors
• Defects from improper mold assembly or handling

For accurate simulation results, please provide the following information:

Don't have all parameters? No problem! We can work with estimated values based on standard practices for your alloy and process. We'll guide you through the data collection process with a detailed questionnaire.

Supported 3D CAD formats:

Recommended (Best Quality):

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

Also Accepted:

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

We provide simulation services for all major casting processes:

✓ Standard Processes (Fixed Price):

• Sand Casting (green sand, resin bonded)
• Permanent Mold / Gravity Die Casting
• Lost Foam Casting
• Investment / Lost-Wax Casting

✓ Special Processes (Custom Quote):

• High Pressure Die Casting (HPDC)
• Low Pressure Die Casting (LPDC)
• Vacuum Casting
• Centrifugal Casting
• Continuous Casting
• Heat Treatment

Standard pricing for sand casting, investment casting, lost foam, and permanent mold:

Analysis Type	First Calculation	Additional Iterations
Solidification Only	€600	€300 (50% off)
Flow & Solidification	€740	€370 (50% off)
Full Package (All 3)	€1,140	€570 (50% off)

Note: Die casting (HPDC, LPDC), vacuum casting, and other special processes require custom quotes. Contact us for pricing.

Average ROI is 5-10x on the first project, with even higher returns for complex or high-volume castings.

Additional benefits not captured in ROI:

• Faster time-to-market (4-10 weeks saved)
• Reduced engineering resource consumption
• Higher product quality and consistency
• Knowledge gained for future projects
• Reduced warranty claims and field failures

Yes! Simulation provides excellent ROI even for low-volume production because the primary savings come from avoiding tooling revisions, not just scrap reduction.

Break-Even Analysis - Scenario: 50-piece production run

Without Simulation:

• 1st trial: 20% scrap (10 pcs @ €200 = €2,000)
• Tooling modification: €8,000
• 2nd trial: 10% scrap (5 pcs = €1,000)
• Total cost: €11,000

With Simulation:

• Simulation service: €740
• One iteration: €370
• 1st production: 3% scrap (2 pcs @ €200 = €400)
• Total cost: €1,510

Key insight: For small runs, the value isn't in reducing scrap (though that helps) - it's in avoiding expensive tooling modifications. Even one avoided tooling change typically pays for multiple simulations.

Simulation services are dramatically more cost-effective for occasional or moderate simulation needs (less than 20-30 projects per year).

Cost Factor	Buy Software	Use Service
Software License (Annual)	€15,000-50,000	€0
Workstation & Hardware	€3,000-10,000	€0
Training (3-6 months)	€20,000-40,000	€0
Engineer Salary (Dedicated)	€50,000-80,000/yr	€0
Year 1 Total	€88,000-180,000	€600 per project

Standard timeline: 3-7 business days from receiving complete project data to delivering results.

Typical Timeline Breakdown:

• Day 0: Data Submission - You submit 3D model and process parameters
• Day 0-1: Review & Setup - We review data, confirm scope, send quote within 24 hours
• Day 1-5: Simulation Execution - Mesh generation, simulation runs, analysis of results
• Day 5-7: Report Preparation - Generate visualizations, compile report, quality review
• Day 7: Delivery - Results sent via email + invoice; download immediately after payment

You'll receive a comprehensive analysis package including:

📊 PDF Technical Report

• Executive summary of findings
• Defect prediction mapping with locations
• Temperature distribution charts
• Hot spot analysis
• Porosity risk zones identification
• Technical commentary and insights

🎬 Process Animations (MP4)

• Filling sequence visualization
• Solidification progression over time
• Temperature evolution
• Flow patterns and velocities
• Phase transformation dynamics

🔧 Interactive 3D Viewer

• Navigate results in 3D space
• Cross-section analysis
• Probe specific locations
• Rotate, zoom, measure
• Export screenshots

💬 Follow-Up Support

• Free Q&A session with engineer
• Clarification of findings
• Implementation guidance
• Technical consultation on results

Casting simulation uses advanced physics-based modeling to virtually replicate your casting process:

The Simulation Workflow:

1. 3D Model Preparation

Your CAD model is converted into a finite element mesh - millions of small elements that allow calculation of physics at every point.

2. Material Properties Assignment

Each component (metal, mold, cores) is assigned thermal and physical properties: thermal conductivity, heat capacity, density, solidification characteristics.

3. Physics Calculations (Multi-Physics Solvers)

• Fluid Dynamics: Simulates molten metal flow, velocity, turbulence
• Thermal Analysis: Calculates heat transfer, cooling, solidification
• Structural Analysis: Computes stresses, strains, deformation

4. Defect Prediction

Results are analyzed using proven criteria functions to identify areas at risk for porosity, hot tears, misruns, and other defects.

5. Results Visualization & Reporting

Engineers interpret results, create visualizations, and prepare comprehensive reports with actionable recommendations.

No! That's the primary benefit of using our service.

What We Provide:

• ✓ Licensed PoligonSoft Software - Full commercial license with all modules and capabilities
• ✓ High-Performance Computing Infrastructure - Dedicated workstations optimized for simulation calculations
• ✓ Expert Engineers - Trained specialists with production experience to interpret results
• ✓ Technical Support - Ongoing assistance with interpreting and implementing findings

You save on:

• €15,000-50,000/year in software licensing fees
• €3,000-10,000 in specialized hardware
• 3-6 months of engineer training time
• €20,000-40,000 in training costs
• Ongoing maintenance and support fees

Absolutely! Root cause analysis of existing production defects is one of our core specialties.

We help foundries troubleshoot quality issues by:

Troubleshooting Process:

1. Simulate Your Current Process "As-Is" - Model your existing gating system and process parameters to identify where and why defects form
2. Compare Simulation with Actual Defects - Validate that simulation accurately predicts your observed defects; provides confidence in proposed solutions
3. Develop & Test Solutions Virtually - Test multiple correction strategies without physical trials; compare different approaches to find optimal solution
4. Validate Before Implementation - Prove that proposed changes will eliminate defects; avoid expensive trial-and-error on production floor

Typical Troubleshooting Scenarios:

• High scrap rates from shrinkage porosity → Identify feeding issues, optimize risers
• Cold shuts or misruns → Adjust pouring temperature, gating modifications
• Hot tears or cracks → Modify cooling rates, reduce thermal gradients
• Inconsistent quality → Identify process sensitivities, establish better controls
• New defects after tooling modification → Understand unintended consequences

Yes, absolutely. Data confidentiality is a top priority.

Our Confidentiality Measures:

• Non-Disclosure Agreements (NDAs) - We sign NDAs upon request before receiving any project files. Many aerospace and defense contractors trust us with their most sensitive designs.
• Secure Data Storage - All project files are stored on encrypted, access-controlled servers. Only assigned engineers have access to your specific project.
• Zero Third-Party Sharing - Your models, process parameters, and simulation results are NEVER shared with any third parties or used for any purpose other than your project.
• Data Retention Policy - Files are retained only as long as needed for project completion and follow-up support. Upon request, we can delete all project data immediately after delivery.
• Trained Staff - All team members are trained in confidentiality protocols and understand the sensitivity of proprietary design information.

Industries trusting us with sensitive data: Aerospace (turbine components), Defense (military applications), Medical (implants), Automotive (proprietary designs), Energy (nuclear components).

We work primarily remotely for maximum efficiency and cost-effectiveness. No on-site visit is required for standard simulation services.

✓ Standard Service (Remote):

• You submit 3D models and parameters electronically
• We perform all simulation work remotely
• Results delivered via email/download
• Q&A via phone/video conference
• Benefits: Faster turnaround, lower cost, no travel logistics

⚙️ On-Site Available (Optional):

• Foundry technology audits
• Production process observation
• Trial casting supervision
• Implementation support
• Team training
• Cost: Custom quote, travel expenses additional

Remote work is possible because:

• All necessary information (geometry, parameters) can be provided digitally
• Simulation is performed on computer, no physical access needed
• Results are easily shared electronically (PDF, videos, viewers)
• Video conferencing enables effective technical discussions

The packages differ in which physics solvers are used and what defects can be predicted:

BASIC: Solidification Only - €600

What it includes: Thermal analysis assuming instantaneous filling (no flow simulation).

Best for: Simple geometries where flow isn't critical, gravity-poured castings with slow gentle fill, or when focusing strictly on shrinkage.

Predicts: Hot spots, shrinkage porosity, solidification sequence, feeding effectiveness.

STANDARD: Flow & Solidification - €740 ⭐ Popular

What it includes: Complete mold filling simulation + thermal analysis.

Best for: Most casting projects (recommended default), optimizing gating systems, and understanding metal flow patterns.

Predicts: Everything in Basic + cold shuts, misruns, mold erosion risks, turbulence zones, hydrostatic pressure distribution.

FULL: Full Cycle (All 3 Solvers) - €1,140

What it includes: Flow + Solidification + Stress analysis.

Best for: Critical components, parts with a history of cracking/tearing, high precision requirements, and dimensional stability concerns.

Predicts: Everything in Standard + hot tears, cold cracks, residual stresses, warpage, dimensional distortion.

Yes! Gating system optimization is a core part of our service offering.

Gating Optimization Process:

1. Analyze Current System - Simulate your existing gating to identify flow problems, hot spots, feeding issues
2. Design Alternative Concepts - Develop 3-5 different gating configurations based on best practices and your constraints
3. Virtual Testing - Simulate each option to compare performance, defect risk, material efficiency
4. Recommend Optimal Solution - Select best design with supporting data showing predicted improvements
5. Provide 3D Models - Deliver optimized gating system geometry in STEP format for tooling

Common Optimization Goals:

• Reduce material waste: Minimize gating system weight while maintaining quality
• Improve filling: Eliminate turbulence, cold shuts, air entrapment
• Better feeding: Optimize riser placement and sizing to eliminate shrinkage
• Faster cycle time: Design for quicker solidification without defects
• Lower cost: Reduce complexity, improve yield percentage

We serve manufacturers across industries requiring high-quality metal castings, from heavy machinery to intricate precious metals.

Aerospace

• Turbine blades & structural components
• Thin-walled parts requiring high integrity
• Titanium and Superalloy castings

Automotive

• Engine blocks, cylinder heads, and rims
• Complex transmission housings
• Safety-critical suspension parts

Industrial Machinery & Energy

• Large valves and pumps (pressure tightness)
• Mining wear parts and crushers
• Power generation turbines and impellers

Jewelry & Art (Statuary)

• Precious metal castings (Gold, Platinum, Silver)
• Porosity control in high-value jewelry
• Filling analysis for filigree and thin details
• Bronze sculptures and large art installations

Medical & Precision Components

• Orthopedic implants (Knees, Hips)
• Surgical instruments
• Parts requiring defect-free internal structure

Common Alloy Families: Aluminum, Steel, Cast Iron, Superalloys (Inconel), Precious Metals (Gold, Silver), Brass/Bronze, Titanium.