Altair Case Studies Skaigh Engineering's Journey to Improved Casting with IoT

	Skaigh Engineering's Journey to Improved Casting with IoT Altair

Skaigh Engineering's Journey to Improved Casting with IoT

Altair

Technology Category	Analytics & Modeling - Digital Twin / Simulation Functional Applications - Manufacturing Execution Systems (MES)
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Manufacturing Process Simulation Virtual Training
Services	Testing & Certification Training
Challenge	Skaigh Engineering, a UK-based company specializing in high-quality aluminum gravity die castings, faced several challenges in its manufacturing process. The casting industry is undergoing significant transformations due to increased customer demands and the growing complexity of parts. To stay competitive and grow in the global market, casting manufacturers like Skaigh needed to address issues such as reducing development and manufacturing costs. The company was dealing with wasted time spent on improving customers’ poor manufacturing techniques and long lead times due to trial-and-error development methods involving inherited dies. To improve the development process and address these challenges, Skaigh began exploring the use of simulation. Read More
About Customer	Skaigh Engineering is a company based in Devon, U.K., that specializes in high-quality aluminum gravity die castings. The company serves customers in various industries and offers a turnkey delivery approach that covers casting design, simulation, and manufacturing. Skaigh Engineering provides a range of on-site services, including sand cast prototypes, die and tooling manufacture, sand cores, heat-treatment, various surface finish treatments, and fully machine-customized castings. The organization is committed to giving its customers an edge in a competitive market by providing excellent products and services the first time around. Read More
Solution	Skaigh partnered with Origin Engineering Solutions, an Altair partner that provides design and simulation solutions. They implemented Altair® Inspire™ Cast, a tool that enabled them to reduce costs and lead times. One specific problem they addressed was the redesign of a tool to replace a 15-year-old, worn-out actuator die that was producing too much scrap. Using Inspire Cast, the Skaigh team simulated the old method, visualized the part filling, and corrected casting defects such as air entrapment. They redesigned the gating and sprue system to improve the manufacturing method and reduce scrap output. In another case, Skaigh used Inspire Cast to address foundry problems causing surface defects on a cast rim. The software revealed air entrapments that had to be removed, leading to a redesign of the part and the elimination of the air entrapments. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Manufacturing Process Simulation

Virtual Training

Services

Testing & Certification

Training

Challenge

Skaigh Engineering, a UK-based company specializing in high-quality aluminum gravity die castings, faced several challenges in its manufacturing process. The casting industry is undergoing significant transformations due to increased customer demands and the growing complexity of parts. To stay competitive and grow in the global market, casting manufacturers like Skaigh needed to address issues such as reducing development and manufacturing costs. The company was dealing with wasted time spent on improving customers’ poor manufacturing techniques and long lead times due to trial-and-error development methods involving inherited dies. To improve the development process and address these challenges, Skaigh began exploring the use of simulation.

About Customer

Skaigh Engineering is a company based in Devon, U.K., that specializes in high-quality aluminum gravity die castings. The company serves customers in various industries and offers a turnkey delivery approach that covers casting design, simulation, and manufacturing. Skaigh Engineering provides a range of on-site services, including sand cast prototypes, die and tooling manufacture, sand cores, heat-treatment, various surface finish treatments, and fully machine-customized castings. The organization is committed to giving its customers an edge in a competitive market by providing excellent products and services the first time around.

Solution

Skaigh partnered with Origin Engineering Solutions, an Altair partner that provides design and simulation solutions. They implemented Altair® Inspire™ Cast, a tool that enabled them to reduce costs and lead times. One specific problem they addressed was the redesign of a tool to replace a 15-year-old, worn-out actuator die that was producing too much scrap. Using Inspire Cast, the Skaigh team simulated the old method, visualized the part filling, and corrected casting defects such as air entrapment. They redesigned the gating and sprue system to improve the manufacturing method and reduce scrap output. In another case, Skaigh used Inspire Cast to address foundry problems causing surface defects on a cast rim. The software revealed air entrapments that had to be removed, leading to a redesign of the part and the elimination of the air entrapments.

Impact #1	The implementation of the Inspire Cast software has brought about significant operational improvements for Skaigh Engineering. The company can now explore more concepts faster and earlier in the development process, spot and eliminate defects, and improve the quality of cast parts. The use of simulation has enhanced the company's understanding of the casting process, allowing it to test theories without the need for prototypes. This has increased customer confidence and saved money by reducing scrap and improving yields. The simulation also bridges skill and knowledge gaps, enabling users to think outside the box and get things done right the first time.

Impact #1

The implementation of the Inspire Cast software has brought about significant operational improvements for Skaigh Engineering. The company can now explore more concepts faster and earlier in the development process, spot and eliminate defects, and improve the quality of cast parts. The use of simulation has enhanced the company's understanding of the casting process, allowing it to test theories without the need for prototypes. This has increased customer confidence and saved money by reducing scrap and improving yields. The simulation also bridges skill and knowledge gaps, enabling users to think outside the box and get things done right the first time.

Benefit #1	Significant reduction in development and manufacturing costs
Benefit #2	Substantial decrease in lead times
Benefit #3	Considerable reduction in scrap output from the actuator die

Benefit #1

Significant reduction in development and manufacturing costs

Benefit #2

Substantial decrease in lead times

Benefit #3

Considerable reduction in scrap output from the actuator die

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Overview

Skaigh Engineering's Journey to Improved Casting with IoT

Operational Impact

Quantitative Benefit