We improve die cast component design to prevent typical HPDC defects and ensure consistent casting quality.
We optimize the component before production, reducing tooling modifications, trials and overall cost.
Porosity, shrinkage and filling issues are common in die casting and often appear only after initial tooling trials.
HPDC process simulation
We use filling and solidification simulations to analyze metal behavior during the casting process.
This allows early identification of porosity, shrinkage, filling defects and critical areas.
We then optimize the design to solve these issues before tooling is manufactured.
Simulation results are used to guide design decisions, reducing trial-and-error during production startup.
- Filling pattern and air entrapment analysis
- Solidification and thermal gradients
- Porosity prediction and defect localization
- Optimization of geometry and wall thickness
- Reduction of tooling iterations
This approach ensures a more stable process and consistent part quality.
How we work
A structured approach to reduce risks, iterations and production issues from the early stages.
Component analysis
Evaluation of geometry, wall thickness and critical areas according to the production process.
Process simulation
Filling and solidification analysis to identify defects and critical zones before tooling.
Design optimization
Geometry refinement to improve filling, solidification and process stability.
Validation
Verification of implemented solutions to ensure consistent component performance.
What we optimize
- Geometry optimization for filling and solidification
- Reduction of defects (porosity, shrinkage, inclusions)
- Design for die casting and manufacturing constraints
- Process simulation (filling and thermal behavior)
- Cost optimization (component and tooling)
Fewer iterations, fewer tooling modifications, lower costs. Faster path to production.
Do you have an HPDC component to develop or optimize?
We analyze feasibility, critical issues and optimization opportunities across design, process and cost.
Get a clear technical assessment to make faster and more informed decisions.