2024 05 Sarginson Studio0116 1 (2)
Challenges • One Piece Castings

One-Piece Castings are Smarter

The economies from merging multiple components into one casting are huge, but maintaining mechanical performance, whilst keeping weight down, makes the engineering complex and the outcomes uncertain. Sarginsons has developed a range of unique technologies to facilitate one piece castings, and has designed and produced many, larger, complex castings as a result.

Large cast components complicate mechanical requirements significantly, as more stress, across a larger form, force a geometric increase in intricacy. Sarginsons accommodates these increased difficulties by simulating these stresses and manipulating material microstructures to achieve required mechanical performance.

With a host of unique technologies Sarginsons can better access the economies of merged components than any other company. 

 

Why Digital Twin Simulations?

The larger a component gets, the more complex and more demanding it becomes to cast and design. Sarginsons is the only company that can accurately simulate the TYE mechanical performance, stress and fatigue of a casting, however large, at any localised point across its form. This allows Sarginsons to virtually test complex designs rapidly, however large or complex.

Topological Optimisation

Larger castings tend to become heavier, but with accurate simulations the design envelope can be challenged by applying full topological optimisation to the component, producing the lightest potential solution. Whilst the organic forms produced would challenge traditional foundries, Sarginsons has developed the techniques and experience to accommodate these challenges.

Intelligent Tooling Works

Sarginsons has been working on more intelligent tooling solutions that integrate 3D printed forms and Smart Cooling as a means of casting the, hitherto impossible, organic forms that topological optimisation creates. Intelligent tooling can overcome most traditional casting issues and Sarginsons Freeform Casting service operates on this basis.

Key Points

  • One Piece Sub-Frames A Speciality
  • Accurately Simulating TYE Is Crucial
  • Heat Treatment Distortion Simulations
  • One Piece Castings Promise Huge Economies
  • Aerospace Quality Standards AchievableĀ 

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One Component, Less Work

The ability to accurately simulate TYE mechanical performance, and predict deformation in heat treatment, removes the principal difficulties of creating larger castings, particularly when merging multiple components.

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