The proposed £6m PIVOT research project will commercialise Sarginsons world leading casting technology in digital simulations, near zero carbon alloys and advanced casting processes. Sarginsons technology, which has upended casting economics and design possibilities, will become far more accessible. And, in so doing, will transform the way OEMs design and conceive components and assemblies - quicker, cheaper, lighter and more sustainable.
The first step in PIVOT is industrialising Sarginsons lightweighting technology, by combining the three separate processes of Metal Solidification, Digital Twin Simulations and Topological Optimisation into one software solution. The second stage is to enhance the strength of recycled aluminium alloys, with the final stage industrialising the organic designs produced through by Topological Optimisation process.
Casting is liquid metal engineering, but it has never been able to truly exploit its infinite design potential, because the number of variables in the casting process is too great to predict or control.
Sarginsons made a huge breakthrough under the LEVA program in being able to accurately run Digital Twin Simulations of TYE mechanical strength, at any specific point, across a form particularly which is an essential step for Topological Optimisation to operate.
This multi-stage process is limited by Sarginsons resources so PIVOT will aim to combine all these simulations technologies into one, user friendly software package capable of being used by OEM designers and foundries alike. PIVOT will democratise casting technology.
Recycled aluminium has lower mechanical strength than primary, which precludes its use in any application where TYE mechanical performance is an issue. Yet, aluminium is far easier to recycle than steel or other metals, so the circular manufacturing dream demands a stronger secondary alloy.
PIVOT will enhance the mechanical performance of secondary aluminium, through Sarginsons technology which uses rare earth metals to refine alloy grain structures, negating weakening caused by iron and oxide contamination.
The net result is that Sarginsons will be able to use 100% recycled aluminium, effectively reducing its components' carbon footprint to near zero. A huge step in sustainable manufacturing.
The last stage of PIVOT will ensure that even the most radical, unconventional and extraordinary designs can be cast. It will leverage the possibilities of 3D printing, Smart Cooling, Intelligent Tooling and Designed Deformation to make the un-castable an everyday event.
PIVOT will change the world. It will transform the economics and performance of aluminium castings, it will make near zero carbon aluminium standard and promote true circular manufacturing standard. Most noticeably, it will transform the look, size, performance and economics of cast components massively changing that market and the manufacturing methodologies for many industries.
