At Ecrimesa Group, simulation and prototyping are not just tools—they are essential steps in the development of new components through investment casting. These processes help us manufacture complex metal parts with greater efficiency, reduced costs, and reliable results that meet each customer’s technical requirements. In this article, we explain how each phase contributes to improving quality and shortening lead times.

Simulation: predicting success before production

Simulation is a powerful tool during the initial design phase. It helps anticipate potential manufacturing issues and optimize geometry for investment casting from the outset, before any physical prototype is created.

At Ecrimesa Group, we use two advanced software solutions: MAGMA and INSPIRECAST. These tools have been specially calibrated with the support of the Technological Center of Components and the University of Cantabria to reflect the physical behavior of our ceramic shell materials. As a result, we can simulate real-world casting conditions with a high degree of accuracy.

Simulation allows us to:

• Predict casting behavior for different designs
• Identify potential defects such as shrinkage or porosity
• Adjust gate positions and wall thicknesses
• Reduce the number of physical trials
• Improve the efficiency of the process from the very first iteration

One of the main benefits of simulation at this stage is being able to advise customers early in the design process. Our technical-commercial team uses the results to propose geometry adjustments that better align with the investment casting process, ultimately helping reduce costs and lead times.

Anticipating casting defects: the hotspot example

Through 3D simulation of a unit part, we analyze key casting parameters, including heat distribution and material flow, to detect hotspots, isolated areas prone to porosity. We can then suggest design modifications or adjust gate placement to improve casting quality. This phase can often be completed in a matter of hours, enabling multiple design iterations in short timeframes.

Once the unit part is optimized, we simulate the full cluster (assembly). Though more time-intensive, this step lets us assess porosity predictions and test different layout options to maximize casting efficiency and part yield.

Simulating the cluster assembly

Once the individual part has been validated, we simulate the complete cluster or assembly, a more complex process that involves modeling the full configuration of parts and their interconnections. Here, we can compare layout options, assess metal distribution, and calculate porosity predictions with greater precision.

Although this step requires more time and resources, it often reduces the number of physical samples needed during the validation phase. It also helps us evaluate whether the part design is suitable for series production, particularly if there are areas where predicted porosity exceeds acceptable limits. Additionally, simulation allows us to explore the possibility of increasing the number of parts per cluster to improve production efficiency.

Moving from simulation to prototyping

Crucially, we often begin building the metal mold while still finalizing prototypes. This parallel workflow helps reduce the overall lead time and allows us to refine the process before finalizing the tool.

Final testing and sample validation

Once the permanent mold is ready, we cast initial samples for mechanical testing and nondestructive inspections. These parts undergo heat treatment and are examined for cracks, dimensional compliance, and metallurgical quality. If needed, minor modifications, such as introducing process-friendly fillets or adjusting features that complicate casting, can still be incorporated before full-scale production.

Through this continuous loop of simulation, prototyping, and testing, we ensure that the final design is not only technically sound but also optimized for casting efficiency and reliability.

Conclusion: why simulation and prototyping make a difference

Simulation and prototyping aren’t just development steps — they’re how we ensure manufacturability, reliability, and efficiency from the very first design review. By identifying casting risks early, reducing iterations, and overlapping tooling with functional testing, we reduce cost and lead time without compromising quality.

This integrated workflow allows our customers to:

• Approve samples with greater confidence
• Validate performance before committing to tooling
• Accelerate the transition to full production
• Reduce development costs and avoid last-minute design changes

For investment casting, that level of control and predictability is critical, especially when tolerances are tight and expectations are high.

How we can support your next project

Whether you’re launching a new part or improving an existing one, our simulation and prototyping capabilities help you make smarter design decisions early on, with fewer surprises later.

Our team works with you from the first CAD model through to series production, combining technical advice, printed wax prototypes, and advanced casting simulation to ensure your part is ready for real-world performance.