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From design
to implementation

Integrated solutions for the production of high-quality molds.

Our range of integrated services for the design, manufacture and optimization of high-quality molds makes us a one-stop company. Our experience and expertise enable us to provide customized solutions that meet the specific needs of our customers in various industries.

Simulation

Our consulting service offers a comprehensive approach to the design and optimization of the casting process, aiming to enhance the performance of the final component and ensure maximum quality.

Thanks to a dedicated team and the use of advanced software, we support our customers at every stage, from 3D model development to final production, providing tailored solutions for every manufacturing need.

360° analysis approach focused on the final component
  • Selection of the most suitable casting technology
  • Development of the entire production process
  • Definition of strategies to meet and achieve project timelines
  • Identification and application of factors that ensure the highest possible quality
  • Definition of appropriate tolerances
Co-design

3D model analysis of the component to identify critical areas and propose improvements that optimize:

  • Component castability
  • Part quality
  • Parting lines to facilitate automated trimming operations
  • Machinability of the casting
Troubleshooting

We offer consulting services not only for the development of new projects but also for the continuous improvement of existing ones:

  • Problem identification
  • Root cause analysis
  • Implementation of corrective actions
  • Monitoring of results

Fast prototyping

We utilize advanced simulation tools to optimize every phase of the casting process. Thanks to our proprietary software, Castle by PiQ2, we can design and validate each step of the production cycle, ensuring precision and quality from the very first stage.

CASTLE by PiQ2

Our simulation system allows us to optimize feeding parameters, verify mold cavity filling, and identify critical points such as air entrapment and hot spots, thereby improving the final product’s performance.

CASTLE software modules:

  • Production scenario simulation
  • Automatic feedback on crucial information
  • First feasibility verification
  • Casting set-up within standard parameters
  • Runner design analysis
  • Optimization of casting shape
  • Simple and fast optimization steps
  • Filling and solidification analysis
  • Airflow and evacuation analysis
  • Thermal behavior analysis of the entire die

Castle is not exclusively used by Costamp. Our software house, PiQ2, markets the software independently.

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Engineering

Each division has a dedicated design department with expertise specific to its technology. Our scope includes:

  • Defining the mold layout and dimensions
  • Determining the casting configuration to facilitate cavity filling and minimize porosity
  • Developing the complete die design
  • Managing the documentation accompanying the equipment

Rapid Prototyping

Thanks to our dedicated Fast prototyping division, we bring our customers’ projects to life by producing aluminum castings, reducing time to market, and optimizing overall costs.

  • Additive manufacturing of sand cores
    • Available in small or large series
    • No shape limitations
    • No size constraints, thanks to the combination of multiple printed parts
  • Sand casting: Raw and finished components
  • Solid block machining for prototype production

Molds

Molds
  • Complete moulds
  • Cavity replacements
  • Maintenance
  • Modifications / changes / set-up
  • Soft tools
Technologies
  • HPDC: Aluminum and magnesium
  • LPDC
  • Plastic
  • Giga
Sizes
  • From 500 to 9000 t

Foundry

Since 2003, Costamp has had an in-house foundry aimed at providing turnkey support to its customers:

  • Dimensional and/or metallurgical sampling
  • Process Development
  • Run@Rate
  • Pre-series / special batches
  • Finished parts production with integrated management of the entire supply chain

Support and training

  • Dedicated project management service
  • Training for customers
    We founded Costamp Academy to provide training services to our customers and make them more independent in mold management and maintenance operations.
  • An immersive experience during assembly phases with the support of our most experienced technicians.
  • On-site support on customer’s site:
TOOLING
  • Dedicated team for die spotting (cold/hot conditions)
  • Disassembly and reassembly operations
  • Troubleshooting
PROCESS
  • Dedicated team for process development support