Casting is the most complex of all manufacturing processes. This complexity is often the culprit for delays and cost over runs in product development, as design ambition runs headlong into the realities of physics; particularly when mechanical strength is an issue. This has often raised the question, how fast can you produce a production ready casting from its model?
With a Digital Twin Simulation to prove TYE mechanical performance and a big 3D sand mould and core printer, it is more than possible to produce production ready, mechanically strong components within 24 hours. Whilst 24 hours is probably not required, it does demonstrate the enormous flexibility of Sarginsons casting prowess and its unrivalled ability to solve casting problems quickly, particularly catching up with development timelines.
Digital Simulations shorten development timelines by enabling virtual testing, permitting Sarginsons to deliver a rapid response protocol that aims to cast components from finalised designs in a day.
Being able to virtually validate solidification, feeds, stress and the TYE mechanical strength of castings, removes the risk of design or production errors, leaving the ability to cast and machine components at speed the only limitation.
As Sarginsons owns pattern making and 3D printing specialist, Pattern Solutions Ltd, and casting machinist, Numachine Ltd, it is perfectly placed to deliver finished castings to the quality standards required within any timeframe, even 24 hours.
This ability to create accurate Digital Twins Simulations of TYE and fatigue, at any point across a components form, allows accurate moulds and processes to be quickly created, for wall thicknesses as low as 2.5mm, for sand and low pressure sand casting. No time is wasted on physical testing, as meeting the required TYE performance is assured by the simulations. This effectively creates an 24 hour emergency supply chain for any cast aluminium component.
Whilst casting a TYE compliant component within 24 hours is not going to be cheap or necessary, it is always cheaper than a production line stoppage. To cast faster than 24 hours will need the Digital Simulations pre-completed in which case the casting of any component within 12 hours may be possible.
Producing castings quickly is all about preparation. And that's where the ability to simulate the mechanical characteristics, stress and fatigue of a component, allows different manufacturing methodologies, without any compromising of component performance, comes into its own.