Simulate Before You Pour: How OneOffCastings.com Delivers Precision One-Off Castings Through Digital Engineering

Why Simulation Matters in One-Off Castings

With one-off castings, there’s no margin for error.

Whether it’s a legacy replacement or a low-volume prototype, every pour must be right the first time. That’s why at OneOffCastings.com, we use simulation—specifically MAGMA solidification modeling—as an essential part of our casting process.

It helps us optimize quality, reduce risk, and deliver castings that meet exacting standards—without second attempts.

Our Approach: One-Off Castings Done Right

Many foundries rely on guesswork or trial-and-error, especially when it comes to low-volume jobs. At OneOffCastings.com, we’ve engineered a different approach.

We apply simulation technology to validate and improve casting integrity before we pour. This ensures:

• Proper gating design

• Optimized solidification

• Defect prevention (shrinkage, porosity, misruns)

• Higher success rates on the first pour

We do this internally, using tools like MAGMA to support our team’s decades of experience in the foundry.

A Process Built for Precision

While every job is different, our workflow is centered on delivering one-off castings with consistency and confidence:

Preparation
We work from customer-supplied data—models, patterns, or physical parts—and prepare them for manufacturing.

Simulation
We use MAGMA to run solidification modeling, identify problem zones, and guide gating and riser design choices.

Production
Once the simulation confirms the part is ready, we pour using our in-house one-off casting process.

Delivery
After finishing and quality checks, the part is shipped out on time and built to spec.

Case Snapshot: Critical Legacy Component Replacement

OneOffCastings was recently approached to produce a replacement for a legacy component no longer in production. With limited documentation and no room for trial-and-error, we applied our simulation-first approach.

Using MAGMA modeling, we validated the gating and solidification before pouring. The result: a flawless, high-integrity casting delivered quickly, with no rework required.

The OneOffCastings.com Difference

We don’t offer consulting. We don’t outsource engineering. We execute.

Everything we do is focused on delivering the one part you need—built right, built fast, and built to spec. Simulation is simply how we ensure that happens.

If you’re replacing a legacy part, fulfilling a low-volume run, or building something unique, we’re ready to help—without guesswork.

Visit OneOffCastings.com to learn more or submit your next project.