Casting Process Optimization
case study
case study
case study example
the problem
A global leader in automotive lighting came to PHB with the challenge of creating two castings – one for low beams and one for high beams. Because of the complexity in aligning the fixtures (heat sink pads) for the LEDs, prior designs had only allowed them to have three heat-sink pads per casting. Since both the low beams and high beams required six heat sinks, each headlight required four castings. The problem compounded when the mirror design was required for left or right headlights. With the added expense of creating separate tooling for all of the castings, and the additional time and expense involved in aiming these eight castings, our customer realized it was time for a new solution.
the solution
The challenge in producing the six heatsink pads was to maintain the profile tolerance to the 6 pads to within .4mm to the datum structure. There are 17 individual features at each pad location, or 102 total features per casting that are critical to function. Any missing feature results in a part that our customer cannot fully assemble. PHB utilized the MAGMA process simulation and other camera quality inspection, close tolerance machining, and precision quality control to develop and produce a two-casting headlight assembly for our customer.
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PHB uses internationally recognized MAGMAsoft® simulation technology to optimize tool design and casting quality. Its optimization capabilities provide a better understanding of mold filling, solidification, mechanical properties, thermal stresses and distortions, and much more. The fully integrated Autonomous Optimization Tool, CAD interfaces, and extensive databases, MAGMAsoft® provides a complete solution for design, production, and quality departments.

MAGMASOFT® provides insights in die casting for:

Casting Quality

  • Optimized gating design
  • Reduced air entrapment
  • Minimize cold shuts
  • Reduced porosity
  • Optimized shot profiles


  • Reduced cycle times
  • Optimized thermal balancing of dies
  • Optimized die spray


  • Fewer tooling modifications
  • Improved die life time
  • Reduced scrap

MAGMAhpdc support for:

  • Shot calculation
  • A complete consideration of process conditions influencing heat flow and die thermal balance
  • A comprehensive visualization of the complete die casting cycle
  • Complete consideration of die cooling and tempering
The MAGMAsoft® module MAGMAhpdc simulates the die casting process based on comprehensive thermal and fluid flow models and takes into account the process and boundary conditions specific to high pressure die casting.

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