Design

Design at Kowala Non-Ferrous Metal Foundry is the first and key stage of every project. We use modern CAD/CAM software and 3D scanning technology to create casting models tailored to client needs and optimized for the production process. 

What does design involve?

Casting design and optimization involves preparing the model and production technology so that the product meets all quality requirements while being as economical to produce as possible. 

Thanks to this approach, the client receives a casting that not only functions as intended, but is also produced faster, at lower cost and with a reduced risk of defects. 

In our foundry the process is as follows: 
Construction Analysis

We check, czy projekt klienta nadaje się do odlewania oraz jakie modyfikacje mogą ułatwić produkcję. 

We introduce the necessary draft angles, machining allowances, and eliminate redundant material.

This is done so that the alloy fills the mold smoothly and casting defects do not occur.

At the client's individual request, we test how the metal will behave in a virtual environment, predicting potential problems and correcting the design before the first pour.

We determine the best material and method (sand casting, die casting) to achieve the optimal balance between durability and cost.

What sets our technology apart?

We cooperate with the Krakow Institute of Technology, which allows us to draw on the latest scientific and practical achievements in the field of casting process design and optimization. This enables us to offer our clients innovative solutions and the highest quality already at the design stage.

KIT

Design Applications at Kowala Foundry

Design of Casting Models and Molds 

  • Development of 3D models of castings and tooling (sand molds, permanent molds, die casting molds). 
  • Selection of appropriate mold parting lines, gating channels, risers and vents. 
  • Optimization in terms of mold longevity and production costs.

Casting Process Optimization

  • Computer simulations of metal flow and solidification.
  • Analysis of defect formation risk (porosity, cracks, misruns, shrinkage cavities). 
  • Selection of the best aluminium alloy and casting parameters.

Design for CNC Machining 

  • Determining machining allowances. 
  • Providing appropriate technological reference surfaces. 
  • Optimizing casting shape to reduce machining time and lower costs. 

Structural and Functional Design

  • FEM analysis (component strength, deformations). 
  • Ensuring dimensional and quality compliance with client requirements. 
  • Weight reduction of the component through appropriate geometry (important e.g. in automotive and aerospace industries).

Ecological and Economic Design 

  • Minimization of material and energy consumption. 
  • Facilitating recycling of castings and gating scrap. 
  • Designing for the minimum number of technological operations.

Sales Support and Client Communication 

  • 3D visualizations of castings for quotes and presentations. 
  • Ability to quickly verify component feasibility already at the quotation stage. 
  • Preparation of technical documentation for the client (drawings, CAD models, simulation reports).

Why choose our foundry?

Our foundry brings 40 years of experience and craftsmanship passed down from generation to generation. We have modern tools that ensure your project will be completed with the utmost care and in the shortest possible time.

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Comprehensive support from concept to finished casting. 
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Modern CAD and casting simulation tools. 
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Optimization of costs, quality and production time. 
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Rapid prototyping and technical consultancy. 
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Experience combined with modern solutions.