The metals industry includes raw and intermediate material processors and specialist manufacturers involved in forging, casting, pressing and other forming operations. Since 1996, we have supplied process modelling and structural analysis software and services to improve material & finished product quality, production efficiency and equipment design.

Software and Consulting

We can simulate most metals manufacturing and heat treatment processes, from preform development and stamping to heat treatment and machining, to predict micro-structural evolution, product defects, tool stress & wear and energy consumption among other results.

Through use of DEFORM, Ansys LS-DYNA and other dedicated software, we help companies to reduce cost, lead time and product imperfections by optimising these processes prior to shop trials. With multiphysics capabilities, complex thermo-mechanical effects can be accurately accounted for, such as phase transformations and latent heat, in addition to the performance of electromagnetic fields during induction heating.

Ingot Conversion Cogging Simulation (Courtesy: NAMTEC)
Ingot conversion cogging simulation (Courtesy: NAMTEC)
Multi-stage hot forging die stress analysis
Multi-stage hot forging die stress analysis
Metal drilling simulation (Courtesy: SFTC)
Metal drilling simulation (Courtesy: SFTC)

Process optimisation consulting projects have included:

  • Investigation of cold forming die failures
  • Prediction of distortion of hot forged railway wheels during cooling
  • Formability assessment of automotive deep drawn panels
  • Optimisation of 3D shearing operations in the aerospace industry
  • Determination of spring-back during dishing processes
Wire drawing (Courtesy: NAMTEC)
Wire drawing (Courtesy: NAMTEC)
Optimisation of perforation pattern for sheet metal forming process (Courtesy: CAE Solutions Ltd)
Optimisation of sheet metal perforation pattern (Courtesy: CAE Solutions Ltd)

Our project work also includes structural assessment and optimisation of heavy duty equipment, including forming presses, shears and furnaces. In addition to consulting, we have supplied Ansys FEA software and training to major equipment manufacturers.

Stress and deflection analysis of aluminium furnace (Courtesy: Mechatherm International Ltd)
Stress and deflection analysis of aluminium furnace (Courtesy: Mechatherm International Ltd)

CFD software is used when the forming material essentially behaves as fluid during manufacture such as during welding or casting. It is also ideal to assess air or water flows around components during heat treatment and cooling, furnace performance and help solve large-scale fluid transport issues within process plant.

Our combination of 3D Ansys fluid dynamics and 1D Flownex software enables any scale of process to be analysed – from tool cooling to pipe network circuits.

Electric slag cleaning furnace thermal design using ANSYS (Courtesy: SNC-Lavalin)
Electric slag cleaning furnace thermal design using ANSYS (Courtesy: SNC-Lavalin)

For clients looking to reduce the cost and downtime of manufacturing operations, our Reliability capabilities can hep determine optimum maintenance strategies for availability and quality, including the capture of plant-specific failure data and generation of well-defined maintenance plans.

As a complementary service, our Safety team can provide hazard analysis services, including HAZOP and SIL assessments, in addition to guidance on systems alarm management.

We are 2nd tier members of the Advanced Forming Research Centre.



We have worked with over 70 companies within the metals industry, including:

Doncasters Blaenavon | Firth Rixson Forgings | Henrob | IMI Yorkshire Fittings | Mechatherm International | Presses Jacks & Hammers Ltd
Rolls-Royce Aerospace | STANLEY Engineered Fastening | Tata Steel Strip Products | Timet UK | VDL Weweler bv

...the support provided by Wilde Analysis has always been exceptional.

University of Sheffield (AMRC)

Excellent support, very rapid and pointed me in the right direction to solve my simulations.

STANLEY Engineered Fastening (Letchworth Garden City)

Using DEFORM, we estimate that we have reduced the number of samples required by around 50%... The confidence acquired in material volume and raw stock size has consented bulk material purchase giving a great reduction on initial lead times. DEFORM 3D is now an integrated part of Cerro EMS’ die design procedure.

Cerro EMS Limited

Manufacturing research is crucial for advancements in quality, production and in reducing the costs associated with the manufacture of parts. Finite element analysis is a powerful tool used to assist this process. DEFORM has been used as a tool to more effectively understand the machining process.

University of Sheffield (AMRC)

....our Design Engineers have all been trained by, and worked with, Wilde Analysis to exploit DEFORM more and more....Wilde Analysis has been there over the years to help us make those key steps forward in our FEA capability.

Stanley Engineering Fastening

Through the years, STANLEY Engineering Fastening’s engineers have experienced many benefits in using DEFORM within product and manufacturing design, rather than simply relying on conventional methods involving trial and error.

Stanley Engineering Fastening

DEFORM has impressive capabilities and applications; the course is extremely useful!….Within three days you will have the ability to work on real applications.

Manufacturing Technology Centre

New and intermediate level users will find this extremely useful to cope with more advanced models and the current expectations in the field of FE modelling of manufacturing operations.

University of Strathclyde (AFRC)

A highly informative meeting, showcasing the new developments in software capability... It was the first UGM for me and I really enjoyed it. It is good to see how much support you can get from SFTC... This meeting provided me with a useful update on the new features in DEFORM.

University of Birmingham (PRISM2)

One on one focus day was an excellent introduction. The level of focused preparation is much appreciated. Your tutors managed to pack a remarkable amount in two days whilst answering all my questions – very useful course.


The course was very well structured and the content was very applicable without being overbearing. The tutor kept the group – which included a wide range of ages and experience levels – engaged at all times and put the information across very clearly. I would definitely recommend the course.

Presses Jacks & Hammers Ltd

Wilde’s team deliver training competently & always have time & patience when required. Highly recommended…..Good facilities, knowledgeable staff

Siemens VAI

The level of support was excellent. My query was dealt with in a speedy and efficient manner with easy to follow instructions which resolved the issue. Thank you.

Timet UK

The [technical support] team is very pro-actively engaged in any problem(s) we may have related to hardware or software. Extremely helpful in any way and any level of support.

Stanley Engineered Fastening

Course provided important information that myself and colleagues have been concerned about when approaching FEA procedures. Knowledge and technique learned will be immediately used in all future projects.

Tata Steel Strip Products

Very informative and professional course.

Timet UK

The course was extremely informative & an ideal introduction to the DEFORM Machining Simulation. … Great people, well planned course, informative materials, excellent refreshment, so thank you very much.

University of Northumbria

How Can We Help?

For more information or to arrange an informal, no-obligation discussion on your requirements, please complete the form opposite or contact us below.

From an initial phone call we can often give you an idea of price and time scales.

With subsequent details, we can then send you some solution ideas, scopes of work and a formal quotation.

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