Design for Manufacturing

Components with engineered quality start here.

Design for manufacturing in metal casting is a crucial discipline that focuses on optimising the production process of metal components. It involves the meticulous consideration of various factors, such as material selection, geometric design, and tooling, to ensure the efficient and cost-effective creation of intricate metal parts through casting techniques. By integrating this approach into the product design phase, Kormax harness the full potential of metal casting, minimising defects, reducing production costs, and ultimately delivering high-quality, durable products to meet both industry standards and customer expectations.

Kormax’s metallurgical team, sales engineers, and quality management teams collaborate closely with clients to offer Design For Manufacturing services, which includes casting design input, material selection advice and optimised production processes through the extensive use of simulation technologies and gained experience.

The design of the component directly impacts the selection of the casting process. Designing with manufacturability in mind from the outset ensures that the casting process is efficient and cost-effective. With over 75 years of knowledge and experience in casting design, Kormax’s team offer valuable input into designs, working with customers to ensure the desired quality of the final product.

With our in-house metallurgical team, Kormax can advise on both the best material for the product’s operational requirement but also the best casting process based on the material. Alloys are a combination of a base metal like Iron, Copper, or Aluminium, all in conjunction with a range of additives. These additives can cause huge changes to the properties of metal even in very small amounts. When the correct, specific alloy or composition is determined, the casting process will begin to take shape. We know that the material properties of the component, such as its melting point, thermal characteristics/solidification nature, and fluidity, need to be considered when selecting a casting process.

With advanced computer simulations, Kormax performs comprehensive assessments of factors such as mold filling, solidification, cooling rates, and potential defects, enabling proactive adjustments and optimisations before physical production takes place. This ensures that we can produce high-quality castings, reliably and with confidence. Additionally, process optimisation and cost reduction further contribute to overall efficiency and competitiveness.