Casting Designs for Manufacturing

Optimising customer designs for precision metal casting

Design for manufacturing in metal casting is a strategic, collaborative approach that optimises customer-supplied component designs for efficient and reliable production. This discipline focuses on key factors such as material selection, geometric suitability, and tooling considerations to improve manufacturability, minimise defects, and reduce production costs. By applying casting design principles early in the project lifecycle, Kormax enhances manufacturability and performance, delivering high-quality castings that meet rigorous industry standards and customer specifications.

Kormax’s metallurgical team, sales engineers, and quality management specialists work closely with clients to review, refine, and optimise existing designs. Our design for casting services include manufacturability feedback, casting-specific design recommendations, material selection guidance, and process optimisation using advanced simulation technologies such as CAD modifications, FEA, and FMEA-ensuring designs are robust, producible, and fit for purpose.

The design of a component has a direct impact on the selection and success of the casting process. Reviewing and optimising designs for manufacturability from the outset leads to more efficient, reliable, and cost-effective casting outcomes. With over 75 years of metal casting experience, Kormax provides expert casting design input and technical feedback, working collaboratively with customers to adjust and refine their designs to achieve optimal casting quality, performance, and compliance with applicable standards.

Kormax’s in-house metallurgical team provides expert recommendations on both the optimal casting material and the most suitable casting process based on material properties. Casting alloys consist of a base metal (such as Iron, Copper, or Aluminium) combined with specific additives that significantly alter mechanical and thermal properties. Even minor alloying adjustments can have a major impact on strength, durability, and performance.

Using advanced simulation technologies, Kormax performs in-depth analyses of mold filling, solidification, cooling rates, and potential defect formation. This proactive approach allows for real-time design refinements, ensuring that casting defects are minimised before production begins. The result is high-quality castings, reliable production, and enhanced cost-efficiency.

Kormax’s commitment to innovation and process optimisation ensures that clients receive exceptional quality castings with improved performance and reduced waste.

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