Get It Right the First Time
Find the Defect Before You Build the Tooling
A shrinkage cavity discovered after the pattern is cut is an expensive lesson: scrapped castings, reworked tooling, and a schedule that slips. Found in simulation, the same problem is a riser moved half an inch in a model.
We run the casting in MAGMASOFT® — the industry standard, developed by MAGMA GmbH — to watch the metal fill and freeze. Turbulence, cold shuts, hot spots, and the exact locations porosity wants to form all show up in the model. Gating and risering are then revised and re-run until the simulation comes back sound.
The alloy databases are calibrated to the metal we actually pour — bronze, aluminum, nickel, and Monel — so the prediction reflects our furnaces and our sand, not a generic estimate. Once the pour is proven, the mold can go straight to sand printing with confidence.
Powered by MAGMASOFT®
Industry-standard casting simulation software — mold filling, solidification, and porosity prediction for all alloys we pour
Services
Simulation Services
MAGMASOFT® simulation is available for new castings, first article support, and production problem solving.
Gating & Risering Design
Before any pattern is built, we use MAGMASOFT® to design the gating system and risering layout. Multiple designs are tested virtually — metal velocity, fill time, temperature distribution, and feeding range are all evaluated to select the optimal system.
Porosity & Shrinkage Prediction
Solidification simulation identifies shrinkage hotspots and predicts where macro- and microporosity will form. Riser size, location, and chill placement are adjusted in the model until the simulation shows a sound, fully-fed casting.
First Article Risk Reduction
For new castings that require first article inspection, simulation dramatically reduces the risk of dimensional or internal quality rejections on the first pour. We deliver castings that pass — not castings that teach us what to fix.
Process Optimization
Simulation is used on existing production castings to improve yield, reduce scrap, or solve recurring quality problems. If you have a casting with chronic porosity or dimensional issues, simulation often identifies the root cause and the fix.
Why Ironbound
Simulation Capabilities
Solidification Analysis
MAGMASOFT® predicts where shrinkage porosity and hot spots will form during solidification — before a single pound of metal is poured. Risers, chills, and gating are optimized virtually to deliver a sound casting from the first pour.
Mold Filling Simulation
Metal flow through the gating system is simulated to identify turbulence, cold shuts, and misruns. We adjust sprue, runner, and gate geometry in the model — not in the mold — saving pattern modification time and scrap.
Thermal & Stress Analysis
MAGMAstress evaluates residual stresses and distortion in the casting during cooling. Critical for tight-tolerance components where dimensional stability matters from the first production casting.
Alloy-Specific Databases
MAGMASOFT® includes validated material databases for bronze, aluminum, nickel, and monel alloys — the exact alloys we pour. Simulation results are calibrated to real foundry conditions, not generic estimates.
Specifications
