Efficient material use by topology optimization integrated with casting simulation
| Reference number | |
| Coordinator | RISE Research Institutes of Sweden AB |
| Funding from Vinnova | SEK 3 976 652 |
| Project duration | September 2022 - October 2025 |
| Status | Completed |
| Venture | The strategic innovation programme for Metallic material |
| Call | Sustainable metal industry - Efficient material flows |
Important results from the project
The project’s objectives have been fulfilled. The methodology has resulted in reduced lead times for prototype development, particularly as certain steps can now be fully or partially automated. At the same time, component weight has been reduced by up to 33% thanks to more efficient material utilization. Through physical and virtual demonstrators, the methodology has been tested on real industrial cast components. The process is now considered as ready for further industrialization.
Expected long term effects
The project demonstrates the potential for increased sustainability and reduced environmental impact through more material-efficient cast products and reduced waste during manufacturing. Taking process limitations into account early in the design process reduces the risk of late redesigns, makes the process more robust, and saves material. Reduced lead times in product development are expected to lead to increased customer value and a more competitive Swedish foundry industry.
Approach and implementation
The OptCast project was carried out as a collaboration between research institutes, industrial partners, and academia. The work followed a structured process of method development, digital workflow integration, and iterative work with physical demonstrators, validated through regular meetings and workshops. Emphasis was placed on early castability, digital simulation, and industrial validation of results.