Services • Consultancy

A Consulting Foundry

Casting is the most complex of all manufacturing methodologies, thanks to seemingly endless variables severely restricting the exploitation of the enormous potential of what is, effectively, liquid metal engineering. Sarginsons unique technologies overcome these issues, opening the door to whole new world of design, performance and cost improvements.

Sarginsons is the only company offering digital twin simulations for cast components that use variable mechanical properties across the cast components form. This allows it to offer a range of unique services from topological lightweighting, to remedial design and weight optimised mega-castings. It's a whole new world.

Sarginsons is an aluminium foundry but it's extraordinary technologies have led to the development of a casting consultancy for OEMS and other foundries alike.

Design for Manufacture (DfM)

The massive potential of Design for Manufacture is well known, but rarely exploited, particularly in the casting industry, despite the potential benefits of DfM in cast components being greater than in any other production methodology. DfM is essentially being ignored.

Sarginsons technology, such as digital twins, allow total DfM to be integrated into every aspect of the manufacturing process realising huge improvements in weight, cost, performance, speed and look. The difference is startling.

Sarginsons DfM+ is exceptional and cannot be ignored.

FEA Mesh Mapping

Sarginsons can now run precise digital twin simulations of variable TYE mechanical performance, at any point across a cast form, and map that data to any FEA mesh.

A revolutionary leap forward that delivers micro-structure aware modelling, integrating as cast porosity, dendrite arm spacing, and eutectic phase distributions directly in hexa/tet meshes. This enables non-linear explicit dynamics, for virtual crash testing, capturing strain rate effects and fracture initiation at SDAS heterogeneities.

No more guesswork - validate against CT-scanned microstructures for mesh convergence you can trust.

Industrialisation Hub

The most fundamental dichotomy in casting is the attempt to ensure production components attain certain performance criteria, without any idea of whether the underlying design is capable of doing so. Foundries frequently have to adapt inherently uncastable designs leading to additional cost and performance compromises.

As Sarginsons can precisely simulate components mechanical performance this is all unnecessary. The process of industrialising castings can be largely simulated allowing all modifications to happen during the design stage. And Sarginsons does this for other foundries as well as OEMS.

Why complicate casting by accepting unnecessary risk and complication? Let Sarginsons take the strains and stresses away.

Perfect Prototypes

Another fundamental incongruity in the casting process is prototype castings, which are made and perform totally differently from the components that they are supposedly mimicking. They may look the same, but what's their point if they don't act the same?

Sarginsons prototypes are different, because they can simulate the exact mechanical characteristics of the production casting and manipulate the prototype's TYE performance to replicate those criteria. A huge step forward.

Getting a prototype right brings a host of commercial and performance benefits: massive lightweighting and cost reduction potential to sharply reduced timelines and markedly improved designs.

Perfect Cast Prototypes are a unique Sarginsons offering that totally change the dynamics of the casting industry.

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Casting Remediation

Sarginsons experience with complex, geometrically challenging castings has given it a unique ability to 'fix' castings that are already in production. Problems created by difficult to cast designs, poor metallurgy, or complex processes frequently cause costly and uncertain component production.

Sarginsons ability to precisely simulate the mechanical characteristics of a casting allows it to virtually test potential solutions, without interrupting production, making process remediation pain free.

Sarginsons is happy to consult on improving difficult castings, with no expectation of production, and has done so for many foundries and OEMs over the years.

Good enough is not good enough.

Rapid Iterative Design

Sarginsons breakthrough with Digital Twin Simulations allows rapid iterative design to be utilised in evaluating multiple design permutations; producing optimal designs by mimicking nature's evolutionary approach, particularly when combined with optimised topology.

By reducing the number of variables and narrowing the range of design options, Sarginsons releases the potential of iterative design in casting. The time consuming, expensive lottery of physically testing cast components is rendered moot through accurate, rapid simulations.

These simulations are further enhanced, by Sarginsons ability to produce prototypes that perfectly replicate the mechanical performance of production castings. Cutting edge design pushes technical boundaries without breaching cost and time limitations.

Perfect is the enemy of good, but that's no reason not to seek it.

Virtual Supply Chain

A unique service that ensures an emergency casting supply by identifying and pre-preparing soft elements, (PPAP, CNC programming) and finding rapid casting solutions, in advance, for those hard production issues (Tools, Fixtures). The aim is to determine a supply solution in the time between production ceasing and component stock exhaustion.

Whilst it is hoped that this service will never be required, the fact it exists serves to reduce the risk of single source supply, mitigating insurance costs, whilst improving peace of mind at a cost substantially less than of dual sourcing.

This service is usually independent of Sarginsons role as an aluminium foundry, although it usually operates alongside Sarginsons sourcing components from abroad.