Quantifying Casting Risk Using Virtual Manufacturing Tools

Move Risk Detection from Production to Design

Traditional trial-and-error foundry methods are costly, slow, and often reveal defects only after production has begun. At that stage, corrective action typically requires additional tooling changes, scrap generation, and expensive rework.

Virtual manufacturing tools shift risk identification to the design phase, enabling engineers to predict, quantify, and mitigate casting failure modes before a single mold is poured. The result is faster qualification, lower risk, and higher confidence in production outcomes.

Gas and shrinkage voids detected early through solidification and feeding analysis.

Flow discontinuities predicted through mold-filling simulation and velocity analysis.

Thermal stress concentrations mapped digitally before tooling investment.

Quantified Risk Leads to Better Decisions

By transforming casting risks into measurable engineering data, simulation enables smarter design decisions, faster process optimization, and predictable manufacturing outcomes with fewer surprises on the foundry floor.

Build Twin

Create a digital model of the casting process

Run Simulation

Analyze filling, thermal behavior, and solidification

Score Risk

Quantify probability and severity of defects

Optimize Design

Prioritize corrective actions with maximum impact

Transforming Simulation Results Into Actionable Decisions

PoligonCast's methodology converts simulation outputs into actionable risk scores. Every potential defect is assigned both a probability index and a severity rating, enabling engineering teams to focus resources on the issues that have the greatest impact on yield, quality, and production performance. The result is a transparent, data-driven decision framework that replaces subjective judgment with measurable risk assessment.

Yield Improvement

Quantified risk analysis helps reduce defects, improve yield, and increase confidence in production outcomes.

Up to 40% Reduction in Casting Defect Rates

Clients report up to 40% reduction in casting defect rates through simulation-driven risk quantification. By identifying and prioritizing potential failure modes before production, PoligonCast delivers lower scrap, fewer iterations, and faster time-to-production.