🔍 Defect Prediction

Identify shrinkage, porosity, and cold shuts before tooling production begins, saving costly rework.

⚡ Rapid Validation

Test multiple gating concepts in days instead of weeks, accelerating your development cycle.

💰 Cost Reduction

Minimize material waste and machining costs by optimizing designs before production.

Our Simulation Process

1
Model Submission

Submit your 2D/3D casting model with process parameters
2
Virtual Analysis

Our engineers run multiple simulations to identify potential issues
3
Optimized Solution

Receive detailed report with animations and recommended improvements

Our Service Packages

Existing Casting Analysis

For foundries looking to improve current production:

Defect root cause analysis
Gating system optimization
Process parameter refinement
Yield improvement solutions

Deliverables:

Detailed report with defect animations and recommended modifications

New Casting Development

For new product development projects:

Complete gating system design
Virtual design validation
Multiple concept evaluation
Production-ready 3D models

Deliverables:

3D models of optimized system + simulation report with animations

Eliminate Casting Defects in Design Phase

Advanced simulation identifies and prevents defects before tooling begins, saving thousands in rework costs

🕳️

Shrinkage Porosity

Problem: Voids formed due to inadequate feeding during solidification

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✔ Preventable in 92% of cases with proper simulation

Simulation Solution:

Predicts hot spots and feeding requirements
Optimizes riser size and placement
Validates chills and cooling rates

❄️

Cold Shuts

Problem: Incomplete fusion of metal streams due to premature cooling

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✔ 87% reduction achievable through flow simulation

Simulation Solution:

Analyzes metal flow front temperature
Optimizes gating velocity and pouring time
Adjusts section thickness transitions

💨

Gas Porosity

Problem: Entrapped air/gas bubbles creating voids

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✔ Detects 95% of potential gas entrapment zones

Simulation Solution:

Tracks air entrapment during filling
Optimizes vent placement and size
Simulates degassing effectiveness

🚫

Misruns

Problem: Incomplete filling of mold cavity

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✔ Eliminates 90% of misrun occurrences

Simulation Solution:

Predicts flow path and filling sequence
Identifies potential flow restrictions
Optimizes gate positions and sizes

🔥

Hot Tears

Problem: Cracks during solidification due to stress

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✔ Reduces hot tearing by 75-85%

Simulation Solution:

Analyzes thermal stress distribution
Optimizes cooling rates and sequences
Modifies geometry to reduce stress concentration

🧱

Inclusions

Problem: Non-metallic particles trapped in casting

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✔ Minimizes inclusion defects by 80%

Simulation Solution:

Tracks particle movement during filling
Optimizes filtering systems
Adjusts flow to prevent slag entrapment

✦ Why Casting Simulation is Essential ✦

Advanced simulation technology transforms traditional foundry operations from trial-and-error to precision engineering

💰

Cost Reduction

Eliminate expensive physical prototypes by validating designs virtually. Simulation reduces material waste by up to 40% and decreases machining costs by identifying optimal gating early.

Typical Savings: $15,000-$50,000 per project in avoided trial costs

⏱️

Time Compression

Reduce development cycles by 50-70% by evaluating multiple design iterations in days instead of weeks. Digital validation accelerates time-to-market for new products.

Case Study: Automotive bracket development reduced from 12 weeks to 3 weeks

🔍

Defect Prevention

Predict and eliminate shrinkage porosity, cold shuts, misruns, and gas entrapment before tooling begins. Simulation provides visual proof of potential defects with 90%+ accuracy.

Industry Data: Reduces scrap rates by 30-60% in production

Foundry Benefits

✓ Optimize yield from existing equipment
✓ Reduce energy consumption per casting
✓ Minimize metallurgical defects
✓ Improve consistency between batches

Tool Maker Benefits

✓ Design right-first-time tooling
✓ Extend mold/die lifespan
✓ Reduce rework iterations
✓ Validate designs before steel cutting

How Simulation Transforms Production

Digital Twin Creation

Precise virtual model of casting system

Filling Analysis

Visualize metal flow & potential defects

Solidification Study

Identify shrinkage & porosity locations

Optimization

Iterative improvements to design

Calculate Your Potential Savings

See how casting simulation can impact your bottom line with our ROI calculator

Estimate Your Savings

Some of the Casting Simulation Results

Flow Velocity

In casting simulations, flow velocity is crucial for predicting how molten metal fills the mold. It helps identify issues like air entrapment, turbulence, and cold shuts, ensuring smooth flow, better mold filling, and improved casting quality.
Flow Temperature

In casting simulations, flow temperature is vital to ensure proper mold filling and solidification. It helps detect risks like cold shuts, misruns, and uneven cooling, enabling optimized gating design and improved casting integrity, surface finish, and mechanical properties.
Air Enrapment

In casting simulations, air entrapment indicates where air may get trapped during metal flow. Monitoring it helps prevent porosity, blowholes, and incomplete filling. Identifying air pockets early allows for better venting and gating design, improving overall casting quality and reliability.
Flow Velocity Vector

In casting simulations, flow velocity vector direction shows the path and behavior of molten metal within the mold. It helps identify turbulence, short-circuiting, and uneven filling, guiding gating system optimization to ensure smooth, uniform flow and high-quality castings.
Fill Time Plot

In casting simulations, the fill time plot shows how long molten metal takes to fill the mold cavity. It helps identify slow-fill zones, cold shuts, and misruns, enabling optimization of gating design for balanced filling, better quality, and defect prevention.
Flow Oxides

In casting simulations, the flow oxides plot highlights areas where oxides may form due to turbulent metal flow. This helps detect risks of inclusions, weak spots, and surface defects, allowing engineers to refine gating and pouring to minimize oxidation-related issues.
Maximum Air Pressure

In casting simulations, the maximum air pressure regions plot identifies areas where trapped air builds up during mold filling. High air pressure can lead to blowholes, porosity, or incomplete filling. This plot guides venting and gating improvements to enhance casting quality.
Materail Trace Lines

In casting simulations, the material trace lines plot tracks the path of molten metal during filling. It helps visualize flow patterns, detect dead zones, and analyze mixing behavior, enabling better gating design and ensuring complete, uniform filling for high-quality castings.
Solidification

In casting simulations, solidification analysis reveals how and where molten metal solidifies in the mold. It helps identify shrinkage defects, hot spots, and non-uniform cooling, allowing optimization of riser design and cooling rates to improve casting quality and integrity.
Shrinkage Porosity

Shrinkage porosity indicates areas where metal volume loss during solidification can create voids. Identifying these zones helps optimize riser placement, cooling rates, and solidification patterns, ensuring sound castings with improved structural integrity and reduced internal defects.
Niyama Mirco-Porosity

Niyama micro porosity predicts the likelihood of micro-porosity formation based on cooling rates and solidification conditions. It helps identify potential defects in fine details, enabling adjustments in gating, cooling systems, and mold design for improved casting quality..
SDAS

Secondary Dendrite Arm Spacing result reveals the cooling rate and solidification structure of the metal. It helps predict material strength, ductility, and defect formation, guiding process adjustments to optimize casting quality and mechanical properties.
Tensile Strength

Tensile strength results predict the material's resistance to deformation under stress. Analyzing these results helps identify potential weak points, optimize alloy composition, and adjust process parameters to ensure castings meet required mechanical properties and performance standards.
Mould-Casting Gap

Mold-casting gap formation during solidification indicates areas where metal shrinks as it cools, potentially leading to misruns or voids. Analyzing this gap helps optimize mold design and riser placement, ensuring complete fill and defect-free castings.
Casting Crack Indicator

The casting crack indicator highlights areas at risk of cracking due to thermal stresses or poor solidification. Identifying these regions helps optimize cooling rates, riser placement, and gating design, preventing cracks and improving casting integrity.
Casting Warpage

Casting distortion/warpage predicts deformation due to uneven cooling or residual stresses. Identify areas prone to shape changes, enabling process adjustments like cooling rate optimization and mold design modifications to prevent dimensional issues and ensure accuracy.