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

Smarter Single Castings

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 the consolidation of multiple components without the traditional risk and uncertainty. 

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 as it can, for the first time, simulate these stresses and manipulate material microstructures to achieve required mechanical performance.

With a host of unique technologies Sarginsons can better access the economies of consolidated 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 locale or point across its form. This allows Sarginsons to virtually test complex designs effectively, however large or complex.

Topological Optimisation

Larger castings tend to become heavier, but with accurate TYE simulations, the design envelope can be challenged by applying full topological optimisation to the component. Whilst the organic forms produced would challenge traditional foundries, Sarginsons has developed techniques to control microstructures which accommodate these challenges. Even for recycled aluminium.

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 techniques such as topological optimisation creates. This opens the door to a whole new world of casting potentialities. 

Key Points

  • One Piece Sub-Frames A Speciality

  • Accurately Simulating TYE Is Crucial

  • Heat Treatment Distortion Simulations

  • One Piece Castings Are Huge Economies

  • Aerospace Needs Component Consolidation 

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One Component, Less Work

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

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