Green sand lines
Sand property control, mold quality scoring, auto-pour control and shakeout timing on high-volume moving lines.
Built for theway your plantactually casts.
Ferrous and non-ferrous. Sand, die, permanent-mold and investment casting. Automotive, energy, aerospace, fluid power and structural components. The loop is the same; the models, windows and evidence are yours.
5Casting methods
6Alloy families
$150M–$30BCustomer revenue range
Built with foundries and die casters melting iron, steel, aluminium, magnesium and copper
Ironhaus GroupMeridian CastingsVulcan DuctileAurora Light MetalsKestrel Die CastingNorthfield Foundry Co.
[PLACEHOLDER] Design-partner names are illustrative until first references are signed.
Five methods,one control loop.
The physics differ. The loop does not: perceive the process, plan against the twin, act inside a window, verify with inspection, log, retrain.
Coremaking
Shot parameters, cure and core strength controlled per core box, with dimensional verification tied to the finished part.
Yield and takt
Moving-line takt balanced against furnace readiness, mold readiness and inspection throughput.
HPDC cells
Shot profile, intensification and die thermal control against predicted porosity, with vacuum and spray parameters in the loop.
LPDC and permanent mold
Fill pressure profiles, die temperature and cycle control tuned to soundness rather than cycle time alone.
Structural megacastings
Large structural aluminium parts where a single reject destroys hours of value and X-ray triage is the bottleneck.
Shell and wax
Shell integrity, preheat and pour temperature control for thin-wall and single-crystal-adjacent work.
Aerospace conformance
AS9100 and NADCAP-aware genealogy, first-article evidence and non-conformance handling built in.
CT-first inspection
CT batch triage as the primary verdict for safety-critical parts, with root cause pushed back to shell and pour.
Aluminium
Hydrogen and inclusion control, degassing verification and shrinkage prediction for lightweighting programs.
Magnesium
Tight thermal and safety envelopes with handling and cover-gas conditions inside the control loop.
Copper alloys
Chemistry and pour-temperature control for pump bodies, fittings and electrical components.
Three buyers,three numbers.
01Rate, quality, scrap, safety
The economic buyer owns production rate, quality, scrap and yield, and safety. They want autonomous, higher-yield, higher-quality casting — and a number that clears a 6–12 month payback on a $15k/month cell.
- Rate that is not capped by pourer availability
- Scrap and rework off the P&L
- Escapes that never reach a customer
- Plant director
- Metallurgist
- Quality engineer
Where a hidden poreis unacceptable.
Automotive & EV
Engine blocks, crankshafts, structural nodes and EV megacastings, where lightweighting and structural casting volume are growing faster than the workforce that pours them.
Aerospace
Investment castings under AS9100 and NADCAP where CT is the verdict and a field escape is unthinkable.
Energy & turbomachinery
Turbine housings, pump bodies and pressure-bearing parts that must hold for decades without a hidden pore or crack.
Fluid power & industrial
Valve bodies, fittings and hydraulic components produced at volume, where scrap and rework quietly consume the margin.
Structural & infrastructure
Structural nodes and pipe fittings that carry stress and pressure for decades under public-safety expectations.
Job shops at volume
Repeat-production foundries with enough casting value in one cell to make the wedge ROI obvious in a single quarter.
QualifyBaselinePilotExpand
Wedge-cell annual pain$500k–$5M
Month payback6–12
Design partners3–5
Anti-ICP · tiny art or jobbing foundriesnot a fit
Anti-ICP · no integration under IP controlsnot a fit
Anti-ICP · wants a horizontal dashboardnot a fit
Fit · repeat production with X-ray or auto-pour dataqualified
Who this isbuilt for — andwho it is not.
We qualify hard, because a pilot that cannot prove ROI wastes a foundry's quarter and ours.
- Sufficient production volume or casting value to make cell ROI obvious
- Existing melt, molding, pouring, inspection and MES systems with API or OT access
- Executive mandate to raise yield or cut scrap and melt loss
- Willingness to run a paid pilot with a defined yield, scrap or porosity success metric
Start where themoney is bleeding.
Every engagement starts with one cell and one measurable number. These are the wedges design partners pick most often.
Robotic pour and fill control
The craft step. Consistency, rate and safety improve together, and misrun and cold-shut scrap falls immediately.
X-ray / CT porosity detection
Where inspection is the bottleneck and escapes are the fear. Grade everything, triage in minutes, attribute root cause upstream.
Melt chemistry optimization
Where energy and heat-to-heat drift dominate. Hold the window, cut melt loss and kWh per tonne.
Sand, mold and core quality
Where rejects trace back to a batch nobody logged. Control the sand system before it reaches the line.
Robotic fettling and finishing
Where the labour shortage bites hardest and the work is most injurious. Finish hands-free and feed the twin.
$500k–$5M
Annual wedge-cell pain we target
6–12
Month payback on a cell
3–5
Design partners in the first phase
$15k
Monthly landing price per cell
[ASPIRATIONAL] Pilot targets from Smelteon's ICP and pricing model.
The reasons wehear most.
Two of our best pourers retire next year. That is the whole business case in one sentence.
We had simulation and we had CT. We had nothing that connected them on the shift that mattered.
Our customer wants genealogy on every casting. Doing that manually is not a plan.
Design-partner voices are illustrative composites of foundry buyer conversations. [PLACEHOLDER — replace with named references after first case studies.]
Find your wedge.
Tell us which cell costs you the most in scrap, rework, melt loss or inspection backlog, and we will baseline it with you.