Reducing Shrinkage Defects Through Integrated Casting Simulation
In modern foundry and manufacturing, shrinkage defects remain one of the most costly and persistent challenges. PoligonCast leverages advanced casting simulation to detect, predict, and eliminate these defects — before a single mold is poured.
What Are Shrinkage Defects?
Shrinkage defects occur when molten metal contracts during solidification, leaving voids, porosity, or surface depressions in the final casting.
Macro Shrinkage
Visible cavities or pipes in thick sections.
Micro Porosity
Microscopic voids distributed through the casting.
Surface Sinks
Depressions on the outer surface of the part.
Uneven heat distribution leads to isolated hot spots that solidify last, creating internal voids.
Insufficient riser size or placement fails to compensate for volumetric contraction.
Poorly designed gates cause turbulent flow and premature solidification at critical zones.
High solidification ranges in certain alloys increase susceptibility to shrinkage porosity.
Root Causes of Shrinkage
Poor Thermal Design
Inadequate Feeding
Gating System Flaws
Alloy Properties
PoligonCast's simulation platform models the entire casting process — from mold filling to solidification — enabling engineers to visualize shrinkage risk zones digitally and optimize designs before physical trials.
Simulates mold filling, cooling, and solidification with high fidelity.
Highlights shrinkage risk zones digitally before tooling begins.
Engineers refine geometry and feeding systems to eliminate defects.
How Integrated Casting Simulation Works
Modeling Process
Risk Visualization
Design Optimization
Key Simulation Capabilities
Typical reduction in shrinkage-related scrap after simulation-driven redesign.
Reduction in physical prototyping iterations, saving time and tooling costs.
Accelerated process qualification from design to production-ready casting.
Simulation-driven engineering transforms quality outcomes — reducing rework, scrap, and costly production delays across every foundry application.
Measurable Impact on Quality & Cost
60%
Defect Reduction
40%
Fewer Trials
3×
Faster Time-to-Cast
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