Sarginsons is an aluminium foundry, but its strategy is all about the technology. It's the pursuit of excellence by finding the best solution to a problem by understanding the underlying why. And this needs research, time and money. All of which Sarginsons has heavily committed to in solving some of the most challenging of casting quandaries.
The application of the answers has been revolutionary. A minimum 30% weight reduction in all castings re-engineered, is the most eye catching, but improvements in development lead times, larger castings, and the reduction of development risk are also game changing. But the possibilities for casting in aerospace applications, will probably prove to be the most fundamental advance.
The research continues into low carbon alloys, component industrialisation, TYE enhancement in sand castings and so on. The list is long, as the long term goal is to fully exploit the infinite design potential of liquid metal engineering, by being able to cast any 3D geometric form for a minimal price.
Casting entire sections of cars in one piece makes sound economic sense. With the development of several casting technologies, many pioneered by Sarginsons, they can also be lighter greener and cheaper.
Sarginsons five years of research into casting aerospace components has produced the technology, such as digital twin simulations, that can produce stronger, greener, and cheaper components through traditional casting techniques.
Prototypes are not production representative as different manufacturing processes result in differing mechanical performance. Sarginsons can manipulate mechanical performance, particularly in sand castings, to create prototypes that exactly mimic production parts. A huge advantage.
Casting TYE mechanically compliant prototypes from CAD, in under 24 hours is feasible, as 3D printed moulds and cores alongside digital twin simulations and Smart Cooling can bypass bottlenecks, whilst ensuring full mechanical integrity.
By combining topological optimisation, enhanced solidification and digital twin simulations to the iterative design process we add intelligence, by focusing the design effort, ensuring the advantages of rapid iteration are available to the casting world.
The Foundry 2030 research project proved conclusively that traditional casting methods, when using accurate digital twin simulations and enhanced alloys, can deliver the reliability, durability and economies that the next generation of aerospace projects demands.
Combining 3D printed cores, sand-moulds and chills with advanced metallurgy, topology and casting simulations totally frees casting from traditional design restrictions. Totally releasing the potential of liquid metal engineering.
Casting is the most complex of all manufacturing processes, but it offers more potential for advancing component design and performance than any other. The intelligent application of better casting technology is the doorway to securing this extraordinary potential, and Sarginsons the leader at doing so.