Conceptual engineering is an important phase of the development process, in which rapid idea capture is paramount. Conceptual design is the explicit construction of ideas or concepts to visualize a product and for alternative designs to evolve. NESTech will take your product from Concept to Reality. Based on customer specifications, we will evaluate numerous concepts and develop the one that best fits the needs. Product Cost, Time to Market and Product Quality are our primary concerns. Our concept design process encompasses digital visualization with 3D layout for packaging studies. While we design we will take care of the down steam applications like simulation, tool design and manufacturing.
NESTech will assist you in any stage of your project. When you work with us, we become an integral part of your team and are fully committed to meeting your project goals and delivery schedules. Our services include model generation, production drawing creation, Tooling, simulation and manufacturing.
We understand that our customers always want to develop efficient methods to reduce the product design cycle time. We help companies automate their design processes through the creation of "Template" parts and assemblies, which reduces the product design cycle considerably. NESTech will also develop "best practices" and process documentation to help automate the creation of similar products.
NESTech engineers have the experience, background and tools to help you convert your ideas into real products.
Road Construction
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Road Construction
Machinery Builders
Onsite and Offsite
Since 8+ years Team of
20+ Engineers
Cast-Designer introduced a cooling channel calculator, it can help the user calculate the total length of the cooling channel with a given production rate. The utility considers many factors such as the part mass and casting alloy, mould size, production rate, cooling channel diameter, media flow speed and heat affection rate. The final result will be a cooling channel diameter and total length.
Now Cast Designer includes One-Button Cooling System Design from Version 6.2
Cast-Designer introduces fast cooling system analysis method to help designer check the cooling system design at the very early stage, it is fully integrated to the cooling system design interface and the user can get result within 3 to 5 minutes.
Cast-Designer's Production Optimizer intelligently adjusts die spray, cooling/heating channels, and cycle timings to maintain optimal mould temperature and boost productivity. It helps avoid defects like cold shuts or die soldering while improving die life and reducing maintenance costs.
Cast-Designer enables full chain simulation by exporting casting results to external CAE tools for structural analysis and lifetime prediction. This provides a more realistic representation of part performance under "as-cast" conditions, including key casting defects.
Cast-Designer uses advanced CFD technology to simulate HPDC processes with precision. It helps optimize gating, venting, and process parameters to improve quality and reduce defects. Extensive support for GIGA Castings
With the Cast-Designer mechanical stress module, the user can make the stress and distortion analysis. The following result could be obtained after the simulation:
Cast-Designer's can simulate real-world casting conditions in LPDC. It features a powerful design wizard, supports variable pressure inputs, and offers pre-defined templates for quick and efficient process setup. Cast-Designer ensures precise thermal control through detailed modelling of cooling systems and timing.
Cast-Designer's core blowing simulation helps optimize the core filling process by analyzing how sand is blown into the core box. It allows users to adjust nozzle and vent positions to ensure proper filling, pressure, and sand density.
When molten metal heats sand cores, chemical binders decompose and release gas. Without proper venting, this gas can enter the metal, causing porosity defects. Cast-Designer simulates core gas behavior to help prevent such issues.
The HPDC Gating Design Wizard streamlines gating design by accepting key casting inputs and delivering optimized results quickly and accurately.
QuickCast enables rapid flow simulation in minutes by simply placing ingates with a point, direction, and weight factor. Ideal for early-stage design, it helps optimize part orientation and gating layout quickly.
QuickCast enables rapid flow simulation in minutes by simply placing ingates with a point, direction, and weight factor. Ideal for early-stage design, it helps optimize part orientation and gating layout quickly.
Place Sprue. To create runner, select an ingate (created in previous step) and pick a point towards sprue, runner automatically created as per width of the ingate size.
select other ingates and points of the desired location of the runner on screen, runner automatically created with correct width, draft, height as required for the ingate
View runners in 3D, runner section width and height gradually reduced with proper draft angle. Each runner width is as per the width required for the ingate.
Select 1st runner as master and select 2nd to merge, runner section of the 1st runner automatically adjusted where 2nd runner is merging. Similarly in the other side runners.
Cast-Designer simplifies complex 3D runner creation using its built-in ParaCAD system. Just define the workspace, build the 3D die face and addendum, and use the 3D runner projection tool to generate a CAD-based 3D runner system with ease.
RED colored region indicates thick region and as well as that cooling is not sufficient, may leave a shrinkage porosity
Cast-Designer revolutionizes cooling system design with SmartCooling and FastCooling, enabling rapid analysis during the early design stage-without requiring full mold geometry or detailed HTC data.
This fast, geometry-based approach helps reduce development time, improve product quality, and extend die service life.
SmartCooling automates die casting cooling system design using AI to create optimized, efficient cooling layouts. The process is 10-30x faster than traditional methods and follows a powerful 3-step approach:
Assign key regions based on metal flow-up to 6 main zones and 24 sub-regions. Set casting/mold materials, cooling properties, and production targets. This forms the foundation for intelligent cooling layout planning.
The AI engine uses defined parameters to auto-generate a complete cooling system with parametric 3D geometry-supporting both standard and jet cooling types. This is the core of SmartCooling intelligence.
Run FastCooling Analysis to evaluate performance. Instantly see the effect of any changes in channel design, position, or cooling power-enabling fast, data-driven optimization and design decisions. An Larger Example shown above.
In complex cooling systems, media flow within the channels can be quite intricate. Performing a thermal and flow simulation provides a detailed examination of both the media flow and temperature distribution. Furthermore, the dynamic heat transfer coefficient (HTC) can be derived from the results of the simulation, which can be used in the most accurate Full-Mould Cyclic Flow-Solidification Simulation.
Assign all key parameters for the flowing medium hot or cold
Complex cooling system in GIGA casting, now can be effectively optimized.
Die-spray is crucial in die casting-poor spray causes thermal shock, die damage, and downtime.
Die casting part quality can be affected during ejection, where parts separate from mold surfaces under force.
The ejection force depends on metal shrinkage and friction at the contact surfaces. Since ejection happens quickly, the static friction coefficient is key to accurate simulation.
Cast-Designer is a comprehensive casting simulation and optimization software used by foundry engineers and designers. It helps in gating system design, defect prediction, solidification analysis, and process optimization for various casting processes.
Cast-Designer supports a wide range of casting processes including High Pressure Die Casting (HPDC), Gravity Casting, Sand Casting, Investment Casting, Low Pressure Die Casting, and Squeeze Casting.
The software runs on Windows 10/11 64-bit systems. Minimum requirements include 16GB RAM (32GB recommended), a dedicated GPU with 4GB VRAM, and an Intel i7 processor or equivalent. SSD storage is recommended for better performance.
Yes, we offer a 30-day fully functional trial version. You can request it through our website, and our technical team will assist you with the installation and provide basic training if needed.
We provide comprehensive support including email support, remote assistance, on-site training (optional), and regular software updates. Our support team is available during business hours with emergency support for critical issues.
Check your casting and predict shrinkage, porosity, flow, air entrapment defects - without incurring tooling costs or waiting for trials. Assess your method for potential defects. Optimize it for quality and yield improvement ...learn more
