Efficient use of materials in the cast components of the future

The importance for sustainability is constantly increasing for both industry and society. To ensure sustainable products, new efficient design tools are required already in the early product development phase. These tools need to ensure that the use of material and energy in the manufacturing process is as low as possible and at the same time secure that the product is optimized for its use as well and suitable to return in a circular flow.

Development of cast components is a very challenging task because of its multidisciplinary nature. It is highly subjective and includes many areas of expertise. In general, the lack of early manufacturing adaptation means late time-consuming iterations which often result in a more heavier product due to that manufacturability is prioritized.  The component is no longer "optimized" in terms of material efficiency.

OptCast will develop new methodology which effectively combine topology optimization with process simulation. This is done by using new geometry description techniques. By using topology optimization, it is possible to determine where material makes the most use of a component and thus also where material savings can be achieved. The goal is to shorten the development time for cast components as well as making them material optimized. The project will demonstrate the methodology by showing a 15% shorter development time and 15% reduced material use.

The expected effect of the project is a completely new simulation tool for the Swedish industry where manufacturability is moved upstream to the early development phases. In addition to a traditional final report with a clear methodology description, an industry training course will also be produced. The plan is to carry out this training within the framework of the Optimization Arena which is run within the national lightweight arena LIGHTer's program at the end of the OptCast project.