SOPHIA® Process
SOPHIA® is a unique investment casting process that enhances component geometry and mechanical properties by using a controlled cooling operation after casting, resulting in a finer and denser microstructure. This makes it ideal for complex, lightweight components, particularly in demanding industries like aerospace and defence.
- Complex geometries
- Tight tolerances
- Excellent surface finish quality
- Finer microstructure
- Denser microstructure
- Improved mechanical properties
- Improved fatigue life
- Less wall thickness dependence
- Smaller dendrite arm spacing (DAS)
- Better moulded eutectic
- Parts for improved fuel efficiency and enhanced overall performance
- Consistent dynamic properties in in-process welding
- Controlled & faster solidification
- No additional modifying process of the melt needed
- High-strength aluminium application for aerospace
- No need for mould angels
- Creates lightweight components
- Has the ability to map undercuts
- Produces near-net-shape characteristics
- Applications for Aerospace:
- Flap fittings
- Handles
- Joysticks
- Casting HP pumps
- LGSCU housings
- Electronics boxes
- Engine castings for turbofans
- And more
Aluminum
- AlSi7Mg0.3 (A356)
- AlSi7Mg0.6 (A357, E357, F357)
- ALSi5CU1.3Mg0.3 (C355)
- AlCu5Ni1.5MnSbCoTiZr (RR350)
What Is the SOPHIA® Process?
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 the SOPHIA® technology.
Inside the SOPHIA® Process
SOPHIA® is recognised as a top-tier casting process with a casting factor of 1, as per CS 25.621 (EASA) standards.
Controlled Casting
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.
Enhanced Mechanical Properties
SOPHIA® offers superior mechanical properties with features like minimum wall thickness, excellent castability, design flexibility, and enhanced weldability, corrosion resistance, and pressure tightness, surpassing conventional casting methods.
BEYOND THE BASICS
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