Skaigh Engineering's Journey to Improved Casting with IoT
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
About The 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.
The 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.
The 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.
Operational Impact
Quantitative Benefit
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