MAGMA IC

NEW SIMULATION SOLUTION FOR INVESTMENT CASTING

Investment Casting Is Different.

Your Simulation Should Be, Too.

Hundreds of part geometries, dozens of alloys, unique ceramic shells, changing production routes. Not exceptions, but everyday reality in investment casting.

MAGMA IC is the first simulation platform developed specifically for investment casting. It helps you optimize the complete process route, establish robust production windows, and understand the economic consequences of every process decision before production starts.

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MAGMA IC

Finally, Simulation That Understands Investment Casting.

Commercial investment casting is an incredibly complex manufacturing process, producing difficult geometries in a diversity of alloys with tailored ceramic shells and highly variable production routes.

Although the process is complex, simulating it shouldn't be. MAGMA IC supports engineers in understanding these complex factors and their interactions before production starts.

Dedicated

Developed specifically for commercial
investment casting and the diversity of materials being cast.

Process-Oriented

Considers relevant process steps, variable thermal conditions, and diverse production routes.

Robust

Supports virtual experimentation of varying casting conditions and the establishment of reliable process windows.

Economic

Compares not only the feasibility of different technical alternatives, but also illustrates their cost consequences.

Understanding before production

Quality Starts Before the First Casting.

Quality problems are often recognized only after trials or even during production. Understanding the root cause and establishing robust process conditions is key.

MAGMA IC makes these interactions visible, supports the systematic evaluation of process windows, and allows alternatives to be evaluated before material, time, and production capacity are committed.

Highlights of MAGMA IC

Robust and Optimized Process Design for Investment Casting.

MAGMA IC combines process-specific simulation capabilities with systematic virtual experimentation and fully integrated technical-economic evaluation.

Ceramic Shell Behavior

Consider your plant-specific shell properties and your dipping and sanding processes, resulting in process-dependent shell thickness.

Complex Process Routes

Evaluate filling, shell cooling, the impact of sand beds, canning, the impact of clustering the shells, controlled cooling, and vacuum and tilt casting conditions.

Robust Process Windows

Use virtual experimentation, conduct virtual Design of Experiments, and utilize optimization to understand process sensitivity and variability.

Technical and Economic Decisions

Compare quality, process capability, lead time, and manufacturing cost before production, using your plant-specific costs and conditions.

Process-specific capabilities

Dedicated Solutions for the Realities of Investment Casting.

Investment casting success depends on every manufacturing step. MAGMA IC optimizes the complete process – from the shell to the finished casting.

Precision and Repeatability

Understand how varying process conditions influence production stability, dimensional accuracy, and surface quality.

Canning

Evaluate how canning changes thermal boundary conditions during solidification and cooling.

Controlled Solidification

Assess how changing thermal conditions, from the shell on a sand bed to controlled cooling through quenching, influence feeding behavior and defect formation.

Process-specific capabilities

Because Quality Doesn’t Begin at Pouring.

Not meeting specifications leads to costly iterations and a loss of customer confidence. MAGMA IC helps fulfill requirements on quality, yield, and production costs before the first shell is dipped.

Tilt Casting

Tilt casting or rotating the shell are only as good as their setup. Interaction between the tree design and control of the rotation determines the outcome. Understanding this interaction before production establishes robust operating conditions while reducing costly trial and error.

Thermal Shell Interactions

MAGMA IC considers all of the factors affecting local thermal conditions of each individual casting including radiation, shading, shell clustering and cooling, and heat accumulation.

Alloys and Materials

From the properties of the shell and its varying local thickness to the diverse world of cast materials such as steels, cobalt-, and nickel-based superalloys − MAGMA IC understands the challenges of material diversity.

Vacuum Casting

Processing under vacuum is required to protect many alloys, but pulling a vacuum also significantly changes the boundary conditions during filling and cooling. MAGMA IC considers diverse manufacturing routes to establish robust process windows.

Quality prediction

Understand Risks That Cannot Be Seen Before Production.

Simulation results are more than just pretty pictures. They provide engineering evidence for the root cause of quality issues.

Filling-Related Defects

Assess temperature loss, flow behavior, and the risk of reoxidation inclusions or oxides during filling.

Porosity and Feeding

Evaluate solidification, feeding conditions, and hidden porosity risks before physical casting trials.

Distortion and Tearing

Casting distortion or hot tearing is not a surprise. It is a consequence. Understanding these effects before production with MAGMA IC improves dimensional accuracy and helps avoid casting cracks.

Precision and Repeatability

Understand how varying process conditions influence the stability of your production, dimensional accuracy, and surface quality.

BUSINESS VALUE

Every Process Decision Is Also a Business Decision.

MAGMA IC doesn't just optimize quality. It helps you understand how technical improvements translate into higher productivity and lower manufacturing costs, in dollars and cents.

Engineering

Assess feasibility, understand process interactions, and compare design and process alternatives.

Production

Define robust operating conditions and reduce quality risks caused by process variability.

Management

Reduce trials and lead times while making
technical-economic trade-offs transparent.

MAGMA IC – Transforming Complexity Into Confidence.

Discuss your investment casting processes, your current simulation approach, and the application of MAGMA IC with our team.

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ABOUT MAGMA

MAGMA stands for robust and innovative casting solutions ...

... as well as a strong partnership with the metal casting industry. By combining casting process knowledge with simulation competence, MAGMA partners with our customers to use our expertise to their advantage in the profitable optimization of castings and casting processes. With a commitment to casting excellence, we actively work with our customers to integrate the progressive technology of simulation into their operations. [READ MORE]