Solidification & Engineering Design
Cast with Confidence — Designed to Perform
At One-Off Castings, we don’t guess — we simulate. Every one-off part we cast begins with a deep engineering review and full solidification simulation using industry-leading software. From gating to cooling to material flow, we digitally design and test your part before a single ounce of metal is poured. The result? A better casting. Every time.
Why Solidification Modeling Matters
Casting is as much science as it is craftsmanship. But without simulation, flaws like porosity, shrinkage, or incomplete fills can jeopardize a project—especially when you only get one shot.
That’s why we run solidification modeling on all complex castings and one-offs. This predictive engineering approach lets us:
Eliminate shrinkage and porosity before it happens
Optimize gating and riser design for proper flow and fill
Ensure metallurgical soundness across the entire part
Shorten lead times by getting it right the first time
Reduce rework and scrap, even on first-article prototype
Designed for One-Off Success
When you only need one part, there’s no margin for error. That’s why our engineering design process is built to de-risk complexity, accelerate production, and guarantee a better casting outcome.
From reverse-engineered repairs to new component designs, our digital-first approach ensures you get a casting that works—before it’s ever made.
Engineering Tools We Use
Our engineering team leverages the following advanced software to evaluate every part:
MAGMASOFT – Full solidification simulation and gating analysis
NovaFlow & Solid – Real-time flow and fill modeling
CAD Integration – Fully integrated with your native CAD files
DFM Review – Design-for-manufacturability support from day one