Services • Consultancy

A Consulting Foundry

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

The core of Sarginsons advantage is its unique ability to determine variable, heterogenous TYE data, at any point on a cast form, and export that to FEA meshes for full dynamic testing. This ability to properly simulate mechanical performance in a casting changes everything. It opens the door to full topological lightweighting, remedial design and mega-castings consolidating numerous components.

The casting industry just changed. Dramatically.

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, timelines and design. The difference is startling.

Sarginsons DfM+ means huge casting economies

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 mechanical performance, without any idea of whether the underlying design is capable of doing so. All because FEA simulations are unreliable. Until now.

Sarginsons developed its industrialisation Hub to close the gap between an OEM's desired performance and the foundries ability to deliver such. The world's first FEA casting simulation is a great start, but it requires other Sarginsons technologies to fully exploit this freedom.

Why complicate casting by accepting unnecessary risk and complication? Simulate property.

Perfect Prototypes

Another fundamental incongruity in the casting process is prototype castings, which perform totally differently from the production components they are supposedly replicating. They look the same, but what's their value if they don't perform the same?

Sarginsons prototypes are different, because they replicate the precise production TYE mechanical characteristics and, hence, its performance. So Sarginsons prototypes perfected for dynamic testing and short production runs.

The ability to test perfect prototypes generates a host of commercial and performance benefits as well as the potential to sharply reduce timelines and markedly improve 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 cause costly and unreliable production.

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

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 to mimic nature's evolutionary approach to perfecting design, particularly when combined with optimised topology and Sarginsons other casting technology.

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.

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.