Foundry technology, casting process simulation with WinCast® expert and contract manufacturing of castings from a few grams to 200 t
RWP GmbH (Marke iFound)
Roetgen, GermanyNew on Amplifa
About iFound
RWP GmbH operates under the iFound brand as a German full-service provider for engineering, consulting and foundry technology and has its own manufacturing capacity (contract manufacturing). The company produces castings from ferrous and non-ferrous metals in a weight range from a few grams up to 200 tonnes with wall thicknesses from 0.6 mm. Covered casting processes include sand casting, investment casting (lost-wax process, incl. VCIC vacuum centrifugal investment casting for thin-walled parts), permanent mold casting (gravity, LPDC, HPDC), die casting, centrifugal casting, continuous casting and plaster casting, complemented by heat treatment and special processes. In-house developments include Core Block Cooling Technology (CBC) for sand casting, High Performance Iron (HPI) and high-aluminum cast iron. Since 1984, the company has developed the casting process simulation software WinCast® expert, which is used for mold filling, solidification, stress analysis and other parameters and is used worldwide by hundreds of users. The range of services also includes FEM analysis, toolmaking, total quality management with risk and failure analysis, DFM, inspection and auditing as well as digitalization of foundries (Industry 4.0). The headquarters is located in Roetgen, Germany; activities extend worldwide to foundries and manufacturers of all sizes.
- Site
- Roetgen
- Processes
- Sand casting (incl. CBC Core Block Cooling Technology), Investment casting (lost-wax), VCIC vacuum centrifugal investment casting for thin-walled castings, Permanent mold casting (gravity casting, LPDC, HPDC), Die casting (HPDC), Centrifugal casting, Continuous casting, Plaster casting, Heat treatment
- Materials
- Steel (alloyed steel, iron alloys, stainless BCC & FCC, tool steel), Spheroidal graphite cast iron, Grey cast iron, Hematite cast iron, Malleable cast iron, High-aluminum cast iron, High Performance Iron (HPI), Aluminum
- Certificates
- Quality control / Inspection / Audit, Risk and failure analysis, DFM (Design for Manufacturability)
- Industries
- Foundries, Metal industry, Manufacturers (cross-industry)
- 01
Consulting / Engineering (DFM)
- 02
Casting process simulation (WinCast® expert) / FEM analysis
- 03
Toolmaking
- 04
Casting processes (sand, investment, permanent mold, die, centrifugal,
- 05
Heat treatment
- 06
Quality control / Inspection / Audit
Locations
Roetgen
DEHeadquarters with own foundry (contract manufacturing)
- Part weight / size
- a few grams to 200 t
- Materials
- Steel, cast iron, aluminum, copper, bronze, brass, zinc
- Foundry (in-house manufacturing capability)
- WinCast® expert casting process simulation
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Sand casting (incl. CBC Core Block Cooling Technology)Casting | – | – | a few grams – 200 tonnes | – | Steel (alloyed steel, iron alloys, stainless), Cast iron (spheroidal graphite, grey iron, hematite,, Aluminum, Copper, Bronze, Brass, Zinc |
| Investment casting (lost-wax), VCIC vacuum centrifugal investment casting for thin-walled castingsCasting | – | – | a few grams – 200 tonnes | – | Steel, Cast iron, Aluminum, Copper, Bronze, Brass, Zinc |
| Permanent mold casting (gravity casting, LPDC, HPDC)Casting | – | – | a few grams – 200 tonnes | – | Aluminum, Copper, Bronze, Brass, Zinc, Cast iron, Steel |
| Die casting (HPDC)Casting | – | – | a few grams – 200 tonnes | – | Aluminum, Zinc, Copper, Brass |
| Centrifugal castingCasting | – | – | a few grams – 200 tonnes | – | Steel, Cast iron, Aluminum, Copper, Bronze, Brass, Zinc |
| Continuous castingCasting | – | – | a few grams – 200 tonnes | – | Steel, Cast iron, Aluminum, Copper, Bronze, Brass, Zinc |
| Plaster castingCasting | – | – | a few grams – 200 tonnes | – | Aluminum, Zinc, Copper, Brass |
| Heat treatmentHeat treatment | – | – | – | – | Steel, Cast iron, Aluminum, Copper, Bronze, Brass, Zinc |
| Special processesCasting | – | – | – | – | – |
| Casting process simulation (WinCast® expert: mold filling, solidification, stress analysis, coreEngineering | – | – | – | – | – |
| FEM analysis / SimulationEngineering | – | – | – | – | – |
| ToolmakingEngineering | – | – | – | – | – |
| Design for Manufacturability (DFM) / Total quality management, risk and failure analysisTesting | – | – | – | – | – |
| Contract manufacturing (toll manufacturing) with own foundryCasting | – | – | a few grams – 200 tonnes | – | Steel, Cast iron, Aluminum, Copper, Bronze, Brass, Zinc |
2 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Foundry (own in-house manufacturing capability) | – | – | – | – | Roetgen, Germany |
| Casting process simulation software WinCast® expert (developed since 1984) | RWP GmbH / iFound WinCast® expert | 1 | – | 1984 | Roetgen, Germany |
Additional services
Quality
Total quality management comprises risk and failure analysis, quality control, inspection and auditing as well as design for manufacturability (DFM). Casting process simulation with WinCast® expert serves to safeguard quality in every project.
| Evidence | Roetgen |
|---|---|
| Quality control / Inspection / Audit | |
| Risk and failure analysis | |
| DFM (Design for Manufacturability) |
History
- 1984
Development of the casting process simulation software WinCast® expert
- 2017
Dr.-Ing. Konrad Weiß received the Chinese Friendship Award in Beijing, presented by Vice Premier Ma Kai