One Piece Cast Supercar
Solutions • An Iterative Design Solution

Supercharged Iterative Design

The enormous number of variables in the casting process means the idea of rapid iterative design is usually impractical, particularly given the costs and time of physical testing. Sarginsons makes iterative design a reality through its digital twin simulations being able to intelligently refine options generated by the casting software.

Numerous designs can be virtually tested for localised TYE performance, through digital twin simulations, with the results fed back into the next iterative cycle. This simulated, iterative approach opens the door to more radical and creative designs, and allows boundaries to be pushed without concern to development timelines.

For the first time, rapid iterative design is a viable design methodology for cast components. For the first time designers will be able to truly exploit the unlimited design potential of liquid metal engineering. 

More Mass, Less Strength

Sarginsons were asked to reassess the design of an existing casting, where the OEM had added mass to compensate for high stress areas. This had reduced performance, because a homogenous approach to TYE mechanical strength had been assumed, rather than generating a disparate, localised simulation of TYE. Sarginsons used an iterative design process, conditioned by simulations, to rapidly qualify proposed solutions.

Simulations Change Everything

The integrated use of advanced casting simulation with optimised topology was key to maximising the lightweighting opportunity. By fully understanding the impact of organic geometry on cooling rates, manufacturability, and mechanical strength the casting was made lighter and stronger, whilst performance was improved. 

A 30% Weight Reduction

Accurately simulating mechanical strength at all points across the casting’s form allowed a direct connection to microstructural solidification, enabling a ‘less is more’ approach to create a skeletal, lightweight structure that met or exceeded all TYE requirements with a 30% reduction in mass; TYE simulated accuracy was within 2% of actual.

Key Points

  • TYE Simulations Empower Iterative Design 
  • Lightweighting Needs Localised TYE Simulations 
  • More Mass Can Reduce Strength
  • Component Geometry Influences Cooling
  • Simulated TYE Was Within 2% of Actual

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Trial and Error But Turbocharged

Sarginsons have developed systems that generate several design routes for each component analysed. Simulations decide which show the most promise and these are developed further through topological optimisation and the process repeated.

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