Thanks to the huge number of variables, casting is the most complex of all manufacturing disciplines. Without understanding each nuance, each discipline and the relationships between them it is difficult to minimise production costs, without compromising performance.
Sarginsons DfM+ considers every aspect of component development from alloy selection, design, solidification, and simulation through to CNC machining, heat treatment and robotic handling: every single step and process is considered. The Sarginsons Technology Centre was developed with this in mind and it's focus is on developing technology that cuts casting costs.
It’s axiomatic that simple design is the best design, but simplification demands true understanding, which has to be earned through research, mistakes and investment. All of which Sarginsons has experienced, suffered and spent over many years.
The easiest way to reduce costs is through good design. Especially if that design encompasses expertise and unique technology for every aspect of the production process. Starting with generative design, verified through localised TYE simulation, and perfected through topological optimisation. All whilst considering alloy selection, heat treatment, tool design and a long list of other skillsets.
Merging multiple components into one casting is a huge economy. Sarginsons has been designing one piece castings for years, relying on its simulation technology for precise TYE mechanical performance data. And Sarginsons has invested heavily in equipment capable of casting and processing larger components.
The move from prototype to production component is particularly problematic in casting, as the prototypes don't replicate production component characteristics, making the industrialisation process uncertain and expensive. Sarginsons unique technology avoids these difficulties, minimising cost whilst reducing timelines.
Focussing on the technology of aluminium casting improves Sarginsons ability to control the variables and uncertainties of the casting process, enhancing design flexibility whilst improving component performance and reducing costs.