Digital precision metal casting insights

Benefits

Why choose the SOPHIA® process?

Our SOPHIA® process is the smart choice for projects that require:

Complex geometries
Tight tolerances
Excellent surface finish quality
Finer microstructure
Denser microstructure
Improved mechanical properties
Improved fatigue life
Reduced dependence on wall thickness
Smaller dendrite arm spacing (DAS)
Better-formed eutectic
Components for improved fuel efficiency and enhanced overall performance
Consistent dynamic properties during in-process welding

Key features

A look at the key features of the SOPHIA® process

Key features of our advanced proprietary SOPHIA® process include:

Controlled, faster solidification
No additional melt modification required
High-strength aluminium applications for aerospace
No need for mould angles
Lightweight components
Ability to map undercuts
Near-net-shape characteristics
Aerospace applications:
Flap fittings
Handles
Joysticks
HP pump castings
LGSCU housings
Electronics boxes
Turbofan engine castings
And more

Compatible materials

Choose your SOPHIA® process materials

Our wide range of materials compatible with the SOPHIA® process includes:

Aluminium
AlSi7Mg0.3 (A356)
AlSi7Mg0.6 (A357, E357, F357)
ALSi5CU1.3Mg0.3 (C355)
AlCu5Ni1.5MnSbCoTiZr (RR350)

The SOPHIA® process is a cutting-edge investment casting method renowned for its precision and innovation, particularly in aerospace, defence and specialised applications. By employing a controlled cooling process, SOPHIA® optimises component geometry and enhances mechanical properties, delivering superior strength and fatigue resistance. This technology enables the production of complex, lightweight components with exceptional surface quality and material flexibility, making it a critical asset for meeting stringent industry requirements. We are one of only four foundries worldwide capable of casting with SOPHIA® technology.

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SOPHIA® is recognised as a top-tier casting process with a casting factor of 1, in accordance with CS 25.621 (EASA) standards.

Rigorous process controls—such as precise adjustments to mould time and temperature, transfer times, metal temperature, spectral analysis and density index—ensure that the casting process is both reliable and consistent.

SOPHIA® offers superior mechanical properties with features such as minimum wall thickness, excellent castability, design flexibility and enhanced weldability, corrosion resistance and pressure tightness, surpassing conventional casting methods.