Home - Arc Impact Debuts Digital Casting Services for Defense Manufacturers Defense Arc Impact Debuts Digital Casting Services for Defense Manufacturers Aura Moreno 28 minutes ago 0 Additive manufacturing (AM) company Arc Impact is promoting Digital Casting Services, a workflow that pairs simulation with 3D printed sand molds and cores to help defense and government programs manufacture complex castings with fewer failed pours. The company positions the offering as a way to recover obsolete or hard-to-source parts and bring idle equipment back into service without relying on original patterns or tooling. Modeling the Pour Before Production Begins Arc Impact says casting complex or high-value parts carries significant risk because defects such as hot spots, uneven feed paths, and shrinkage often surface only after a part has already been poured and inspected. To address this, Digital Casting Services incorporates fluid-flow and solidification modeling upfront, mapping how molten metal will fill a mold cavity and solidify before any physical pour takes place. The company says this modeling applies to conventionally tooled molds as well as printed ones, letting engineers adjust rigging and risers digitally reducing the need for repeated physical tests. The company argues that traditional pattern-based mold making constrains what a simulation can actually recommend, since draft angles, parting lines, and multi-piece core assemblies limit which geometries can be produced. Because its molds and cores print directly from CAD files, Arc Impact says it can produce gating and runner shapes suited to flow requirements, along with internal passages formed as a single monolithic core instead of an assembled one. Consolidating multiple core-box components into one 3D printed piece, the company adds, removes a source of inaccuracy and surface defects tied to assembly, and allows designs to be revised without scrapping or modifying tooling. Arc Impact Introduces Digital Casting Services. Image via Arc Impact. Recovering Legacy Parts for Defense Programs Arc Impact frames part recovery as a central use case for the service, citing obsolete and hard-to-source components as candidates for domestic, on-demand casting that can restore idle or non-functioning equipment to service. The company ties this to government and defense efforts to strengthen manufacturing resilience, positioning the approach as a way to address supply continuity for programs that depend on legacy parts no longer supported by their original tooling. The broader push toward part recovery reflects a recurring theme in metal AM: using digital workflows to reproduce components without the physical tooling those parts originally required. Arc Impact’s casting-specific version applies that logic to sand-cast metal parts in contrast to the powder-bed or directed-energy processes more commonly discussed in the sector.