🛠️Simulation-First Precision for One-Off, Mission-Critical Castings
“You only get one shot at a one‑off casting—so simulation isn’t optional, it’s essential.”
At One Off Castings, every part is digitally forged—fully modeled, simulated, and optimized—before a single drop of metal is poured.
The Four-Step Simulation Process
1. CAD Model Input
The process begins with a precise 3D CAD model, including gating, risers, and mold layout.
2. Solidification Simulation
Using tools like ProCAST, MAGMAsoft, and FLOW‑3D CAST, we simulate molten metal behavior to identify shrinkage, porosity, flow issues, and stress points.
3. Gating & Riser Optimization
Simulation guides iterative changes to gating and risers to ensure smooth fill and optimal solidification.
4. Final Validation
Final simulations confirm metallurgical soundness and structural integrity before any tooling begins.
âś… Why This Matters
Eliminate first-run scrap – Avoid waste, reduce cost.
Accelerate time-to-part – Cut weeks down to hours.
Guarantee performance – Predict material behavior before production.
Perfect for one-offs – Ideal for legacy, prototype, or critical parts.
MAGMAsoft Case Study: Triumph’s Fuel Distributor Housing
A powerful example of simulation-first success comes from MAGMAsoft’s work with Triumph:
Initial designs showed internal porosity in a fuel distributor housing.
MAGMAsoft’s simulation pinpointed the issue, prompting precise adjustments in die cooling.
Follow-up simulations tested new cooling positions and adjusted rib thickness for smoother flow.
These digital iterations resolved the defect—without a single wasted cast.
Result: A fully sound component was produced with no trial-and-error machining or tooling revisions.
You can read the full case study here:
Solving Internal Casting Defects – MAGMAsoft Case Study
One Off Castings: Getting It Right the First Time
Our simulation-first method ensures your parts are forged with accuracy from the first pour. Whether you're replacing a legacy part, launching a prototype, or solving for a critical single-use application, our process saves time, money, and material.
Let’s talk if you’re ready to cast with confidence.
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References
FLOW‑3D CAST – Foundry Simulation Software
ProCAST – ESI Group