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E-Mobility is Creating New Horizons for Foundries

Facing global competition, foundries must strengthen and diversify their offering if they want to grow new business within emerging market segments. In the automotive industry, parts manufacturers need to follow the evolving challenges rising along the development of low emissions, lightweight, electrified vehicles. Today, foundries must equip themselves with tools to support their customers in:

  • achieving premium quality castings with ever growing complexity
  • using more complex die casting processes
  • utilizing innovative, lightweight material like aluminum and magnesium
  • manufacturing innovative parts such as battery housings or electric engine parts

Process simulation, in combination with data analytics allows foundries to face these emerging challenges while controlling cost. This, in turn, allows foundries to optimize their casting processes, get the parts right the first time, decrease scrap rates and ultimately ensure the delivery of high-integrity, high-quality parts in a timely manner.

Whatever your strategy, whatever your challenge, ESI can help you deliver.

Integrating simulation with virtualization of the Casting Machine for a competitive edge

 

 

 

"Today, casting simulation is mandatory and necessary to reach the best quality results, including choosing the right tonnage of the machine to reduce costs. With these results in quality and costs, FAR can be competitive on the market."

  - Gianfranco Lenzi, CEO, FAR srl

Watch the video to learn how FAR extends the capabilities of simulation with a virtualization of their Colosio die casting machines ; optimizing their casting processes to reduce costs, increase quality and be more competitive in the marketplace.

Keep a Competitive Edge with Additive Manufacturing

Technology advancements are allowing foundries to take huge strides in developing highly customizable production processes. Additive manufacturing plays a key role in this transformation. With its ability to easily create complex parts, small series and prototypes – especially for the automotive industry - eliminate tooling costs, reduce turnaround time and improve accuracy, foundries are coming to a point where 3D printing will become imperative to staying competitive.

Additive Manufacturing simulation makes it easy for foundries to implement the most efficient manufacturing processes and deliver the most innovative and qualitative components to their customers. Ultimately, this leads to faster development of high quality & precision parts, getting ahead of part distortion and reducing the trial and error in the development process.

Reaching High Efficiency and Profitability with Big Data Analytics

 

Foundries are operating under pressure as they face increasing challenges. They are introducing new materials, reducing the energy consumption to become a sustainable manufacturer, all the while maintaining profitability. To reach the highest cost-efficiency foundries must develop a well-tuned process where they successfully :

  • Increase OEE by avoiding unexpected machine downtime
  • Identify potential quality deviation earlier and reduce scrap rate
  • Optimize process parameters to minimize energy usage

Big data technologies brings the foundry industry to the next level in terms of efficiency and reliability of their operations, ultimately allowing foundries to enable their engineers to make better and more accurate decisions in the manufacturing process while continuously improving casting quality.

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