Employee dipping investment casting mold into slurry

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 defense.

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Benefits

Key Features

Compatible Materials

Why Choose The

SOPHIA® Process?Our SOPHIA® Process is the smart choice for projects that demand:

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 molded eutectic
Parts for improved fuel efficiency and enhanced overall performance
Consistent dynamic properties in in-process welding

A Look at the Key Features of The

SOPHIA® ProcessKey features of our advanced proprietary SOPHIA® Process includes:

Controlled & faster solidification
No additional modifying process of the melt needed
High-strength aluminum application for aerospace
No need for mold 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

Choose Your

SOPHIA® Process MaterialsOur wide range of materials that are compatible with the SOPHIA® Process includes:

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, defense, and specialized applications. By employing a controlled cooling process, SOPHIA® optimizes 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.

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SOPHIA process of a mold dropping into a liquid medium

Inside the SOPHIA® Process

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

SOPHIA process of the molten metal hardening

Controlled Casting

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

Images of part density with different investment casting processes

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.