2024 05 Sarginson Studio0127 1 (1)
Challenges • Simulations Improve Realities

Digital Twins, Iterative Design

Designing castings has historically, been awkward.  The huge number of variables and the inability to accurately simulate TYE and fatigue, mean castings are usually poorly designed relative to their desired mechanical performance. And it's a failure that has huge component life costs. 

Sarginsons has totally changed this dynamic with its new simulation technology. For the first time heterogenous TYE can be calculated at any point on a component form and that data be exported to FEA meshes for accurate dynamic testing. 

This single step has opened the door to massive lightweighting opportunities, particularly through Topological Optimisation, the consolidation of components into mega-castings, and the ability to deploy virtual iterative design loops to optimise component performance. 

Uncertainty Hinders Creativity

An inability to simulate mechanical performance, and the high cost of physical testing, forces a conservative design approach to cast components which compromises performance,. Sarginsons digital simulations, combined with complementary technologies, mitigates these concerns, allowing creativity to flourish and huge economies to be realised.

A Casting Design Service

To optimise component performance it is best to engage with Sarginsons as early in the design process as possible. The ability to simulate mechanical characteristics, at any point across a casting, is a game changer, made even more potent by a DfM service that integrates every aspect of a casting's manufacture through design iteration.

Designing out Cost

Sarginsons has achieved a minimum 20% reduction in mass on every casting it has studied, but that is just the start of a huge range of economies and a unique service dedicated to cost reduction with improved performance. And technology is the secret behind every step.

Key Points

  • Topological Optimisation is Lightweighting

  • Less Risk Encourages Better Design

  • Simulations are a Designers Best Friend

  • Design for Manufacture is Cost Reduction

  • Virtual Iterative Design is Real

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Good Design, Better Business

Sarginsons has developed simulations of TYE in aluminium castings that are precise at any point on component's form. This is a world first which totally changes what's possible through casting - lighter, stronger, cheaper are just the start. The rest is up to the design engineers.

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