Hotspot Detection
Automated identification of isolated heavy sections that cool slowly and are prone to shrinkage porosity, sink marks, internal cavities, and distortion. Performed within minutes for rapid manufacturability feedback.
- Shrinkage porosity zone prediction
- Sink mark & cavity risk mapping
- Distortion-prone region identification
- Cooling imbalance alerts
Wall Thickness Analysis
Detects thin sections causing misruns and cold shuts, thick sections causing shrinkage, and non-uniform wall transitions that create turbulence, hotspots, and residual stresses.
- Minimum thickness violation detection
- Maximum thickness & section mapping
- Abrupt transition identification
- Better metal flow & uniform cooling
Parting Line & Slider/Core Identification
Determines optimal die separation location for easier mould manufacturing, better casting extraction, and reduced flash formation. Automatically identifies undercuts, side cores, and slider requirements.
- Optimal parting line recommendation
- Undercut & side core detection
- Slider requirement & count estimation
- Simplified die design & reduced tooling cost
Ejection Force & Core Extraction
Predicts force required to eject casting from die to prevent casting damage and optimize ejector pin design. Evaluates core removability and manufacturability to avoid trapped cores.
- Ejection force estimation (N/mm²)
- Ejector pin placement optimization
- Core removability verification
- Trapped core detection & resolution
Gating Wizard
Built using decades of foundry knowledge and industry standards. Automatically recommends machine selection, biscuit dimensions, fill time, gate velocity, runner dimensions, ingate area, and runner area ratios.
- Process-specific recommendations (HPDC/LPDC/Gravity)
- Fill time & gate velocity optimization
- Area ratio calculations (real foundry rules)
- Faster development & reduced dependency on experience
Smart Runner Generator
Designer only defines ingate locations and biscuit location — software automatically generates complete runner system with area reduction rules, draft angles, fillets, branch runners, and main runner balancing.
- Complete runner system in minutes
- Automatic area reduction & balancing
- Draft angles & fillets applied
- Improved casting yield
Predefined Gating Libraries
Comprehensive libraries for Gravity Casting, HPDC, LPDC, GDC, and Investment Casting. Proven design templates enable rapid project setup and standardized gating configurations.
- Industry-standard template collection
- Process-specific runner configurations
- Customizable & expandable library
- Reduced engineering setup time
QuickCast™ Flow Assessment
Geometry-based instant flow assessment without building complete runners or moulds. Users simply select ingate positions — predicts flow path, coverage, filling sequence, dead zones, air entrapment, and gas porosity tendency.
- Results within minutes (not hours/days)
- Early design validation without meshing
- Dead zones & air entrapment mapping
- Significant engineering time savings
AI-Based Pre-Design Optimization
Automatically optimizes ingate location, orientation, size, and metal distribution to achieve uniform filling, balanced flow, and reduced air entrapment — before detailed simulation begins.
- Ingate position & angle optimization
- Metal distribution balancing
- Reduced simulation iterations
- Better first-time-right design
Fast Cooling Analysis
Rapid thermal assessment of the casting providing temperature maps, hotspot regions, and cooling imbalance identification. Enables early thermal validation before detailed cooling design.
- Temperature distribution mapping
- Hotspot & cold spot identification
- Cooling uniformity assessment
- Early thermal feedback in minutes
Automatic AI Cooling Design
Automatically generates cooling channels, cooling layouts, and thermal balancing strategies. Complete cooling system designed in minutes — dramatically reducing die design effort.
- AI-generated channel placement
- Thermal balance optimization
- Reduced die design time (hours→minutes)
- Improved cooling efficiency
Cooling Design Optimization
Further improves cooling efficiency, temperature uniformity, and cycle time. Increases productivity and extends die life through optimized thermal management.
- Cooling channel parameter tuning
- Temperature uniformity optimization
- Cycle time reduction analysis
- Die thermal fatigue mitigation
Advanced CFD Flow & FEM Solidification & Stress
Advanced CFD Flow
The CFD solver accurately captures molten metal behavior, including free-surface flow, turbulence, air entrapment, oxide formation, pressure distribution, and complex filling dynamics — critical for high-quality casting design.
- Free-surface tracking & turbulence modeling
- Air entrapment & oxide formation prediction
- Pressure distribution & velocity profiles
- Non-Newtonian & semi-solid flow capabilities
FEM Solidification & Stress
The FEM solidification solver provides precise thermal analysis, predicting temperature gradients, cooling rates, solidification sequence, and shrinkage defects. Its coupled thermo-mechanical FEM analysis evaluates residual stresses, distortion, hot tearing, and mould gap formation.
- Temperature gradients & cooling rate prediction
- Shrinkage porosity & Niyama micro-porosity
- Residual stress & distortion analysis
- Hot tearing & mould gap formation
Analysis Stage: Comprehensive Simulation Suite
Flow Filling Analysis
Full filling behavior prediction: fluid fraction, temperature evolution, velocity contours, turbulence zones, and air entrapment. Supports HPDC, Gravity, LPDC, GDC, tilt, investment, lost foam, and more.
- Air entrapment & oxide prediction
- Material age & flow trace lines
- Mould erosion / cold shuts & misruns
Solidification & Shrinkage Porosity
Temperature evolution, solid fraction, cooling rates, thermal modulus. Advanced Niyama criterion for micro-porosity, macro shrinkage cavities, and SDAS prediction.
- Macro shrinkage & internal cavities
- Niyama micro-porosity mapping
- Feeding requirement identification
SDAS & Mechanical Properties
Secondary Dendrite Arm Spacing prediction from local solidification conditions. Direct estimation of Ultimate Tensile Strength (UTS) and elongation — virtual quality assessment without test castings.
- Strength & ductility mapping
- Correlation with cooling rate
- Metallurgical quality index
Residual Stress & Distortion
Integrated casting process stress simulation (not generic FEA). Includes thermal history, phase transformations, mould gap effects. Predicts locked-in stresses, warpage, and final dimensional deviations.
- Hot tearing & crack susceptibility
- Mould / casting gap analysis
- Quench & age distortion
Fatigue & Casting Performance
Virtual validation of finished castings under service loads. Unlike traditional FEA, it integrates porosity, gas holes, residual stresses, and actual casting defects to predict fatigue life and failure.
- Cyclic loading / SN-curves
- Failure probability with defects
- Structural + thermal combined
Air Entrapment & Oxide Prediction
Quantifies air pockets, bubble movement, and oxide film formation due to turbulent flow. Critical for reducing gas porosity, surface defects, and improving structural integrity.
- Air pressure & entrapment zones
- Oxide / bifilm index
- Venting optimization guidance
Mould Thermal & Erosion Analysis
Predicts die / mould temperature distribution, hot spots, and erosion-prone regions. Enables optimized cooling channel layout and reduced thermal fatigue.
- Mould erosion severity
- Cycle-to-cycle die stability
- Cooling efficiency index
Shot Sleeve & Piston Simulation
Realistic simulation of slow shot, fast shot, piston movement, metal acceleration, and air compression inside the sleeve. Essential for high-pressure die casting process setup.
- Air entrapped in sleeve
- Wave & velocity profiles
- Optimized biscuit/plunger
Gas & Venting Effectiveness
Predicts trapped gas and movement through the mould, and venting efficiency. Reduces gas porosity defects and improves casting quality.
- Pressure build-up prediction
- Vent placement optimization
- Gas output in each vent vs time
Casting Heat Treatment Simulation
Virtual simulation of solution treatment, quenching, and aging cycles. Predicts microstructure evolution, residual stress changes, and final mechanical properties after heat treatment.
- Quench distortion & residual stress
- Phase transformation kinetics
- Aging response & hardness
Semi-Solid Modeling & Thixo-Moulding
Advanced simulation for semi-solid metal casting processes with critical small process windows. Supports non-Newtonian flow models and multiple material models for thixo-moulding and low solid fraction magnesium alloy casting.
- Non-Newtonian viscosity & shear-thinning behavior
- Temperature control within ±5°C process window
- Local fraction solid & temperature evolution during fill
- Melt viscosity & flow velocity mapping
Giga Casting Simulation & Design
Dedicated tools for large-scale automotive castings (body structures, battery enclosures, eAxles, humanoid robots). Powerful meshing, multicore processing, and specialized design tools for giga casting development.
- FastMesh engine: complex mesh with small feature snap & curvature accuracy
- 300M FEM elements on 128GB RAM · Mixed mesh types
- SmartCooling: AI-driven cooling channel design in few clicks
- Cast-Works solver: parallel computing for thermal, flow & stress
- Mould set stress & distortion analysis for huge FEM models
Advanced Stage: Metallurgical Depth & AI Production Intelligence
Cellular Automata Grain Structure
Predicts microscopic grain nucleation, dendritic growth, and final grain morphology during solidification. Outputs grain size distribution, columnar-to-equiaxed transition, and local crystallographic texture.
- Grain size & morphology maps
- Columnar-to-equiaxed transition (CET)
- Ferrite / pearlite phase evolution
- Local density variations
Full Mould Cyclic Analysis
One of the most advanced capabilities — simulates actual production cycles including filling, cooling channels, die heating, die spray, and multiple consecutive shots. Predicts thermal stabilization, cycle-to-cycle variation, and realistic porosity under steady-state production.
- Warm-up cycles & steady-state equilibrium
- Spray cooling effectiveness per cycle
- True die thermal balance & hot spots
- Cycle time optimization insights
AI-Based Optimization Platform
Target-oriented optimization using Genetic Algorithms, DOE, and Taguchi methods. Automatically optimizes gating design, runner dimensions, cooling system layout, and process parameters to reduce porosity, improve filling, increase yield, and enhance thermal balance.
- Genetic Algorithm (GA) searching thousands of combos
- Design of Experiments (DOE) automated workflows
- Multi-objective Pareto optimization
- Production parameter tuning (cycle time, spray)
Shot Sleeve & Piston Simulation
Realistic simulation of slow shot, fast shot, piston movement, metal acceleration, wave dynamics, and air compression inside the shot sleeve. Critical for high-pressure die casting process setup and defect reduction.
- Air entrapment in sleeve during fill
- Velocity & wave profiles optimization
- Biscuit dimension & plunger tip design
- Transition point optimization
Casting Heat Treatment Simulation
Virtual simulation of complete heat treatment cycles: solution treatment, quenching, and aging. Predicts microstructure evolution, residual stress changes, distortion, and final mechanical properties after thermal processing.
- Quench distortion & residual stress evolution
- Phase transformation kinetics (T6, T5, etc.)
- Aging response & hardness profile
- Reduced physical heat treatment trials
Casting Performance Simulation
Virtual validation of finished casting under service loads — uniquely integrates porosity, gas holes, residual stresses, and actual casting defects. More realistic than traditional FEA with direct correlation to real-world failures.
- Structural analysis with defect mapping
- Thermal-mechanical fatigue prediction
- Failure probability & crack initiation
- Certification-ready performance reports
Microstructure & Phase Analysis
Predicts evolution of ferrite, pearlite, bainite, and other phases during solidification and cooling. Provides local density variations and phase fractions for accurate property estimation.
- Phase fraction & distribution maps
- Local density & micro-shrinkage correlation
- Carbon equivalent & hardenability
- Better porosity & strength estimation
Custom Material Generator
Create proprietary alloys by defining chemical composition. Automatically generates thermodynamic properties, phase diagrams, and complete material database entries for simulation of new alloy development.
- Define custom alloy chemistry
- Generate thermophysical properties
- Phase diagram & solidification range
- Seamless integration into simulation
Squeeze Pin Simulation
Predicts effectiveness of squeeze pins in feeding localized shrinkage zones and eliminating porosity. Optimizes pin location, actuation timing, and pressure for improved casting integrity.
- Localized feeding efficiency
- Pin activation timing optimization
- Pressure distribution mapping
- Porosity reduction validation
Production Optimization
Optimizes cycle time, cooling duration, spray strategy, and die thermal balance for maximum productivity. Reduces manufacturing cost while maintaining casting quality.
- Cycle time reduction analysis
- Spray timing & intensity optimization
- Die life extension through thermal balance
- OEE (Overall Equipment Effectiveness) improvement
Genetic Algorithm (GA) Optimization
Searches thousands of design combinations automatically using evolutionary algorithms. Faster convergence to optimal gating, runner, and process parameter designs with multi-objective trade-off analysis.
- Multi-objective Pareto optimization
- Automated design space exploration
- Convergence to global optimum
- Integration with DOE & machine learning
DOE & Taguchi Optimization
Performs automated Design of Experiments to identify optimal process windows. Taguchi methods for robust design — finds parameter settings that minimize defect sensitivity to variations.
- Main effects & interaction analysis
- Signal-to-noise ratio optimization
- Process capability prediction
- Reduced physical trials (up to 80%)
Spray Cooling Design & Optimization
Design and optimization of spray locations, timing, intensity, and pattern for die thermal management. Achieves better thermal stability, reduced cycle time, and improved casting quality.
- Spray nozzle placement & angle
- Flow rate & intermittent spraying
- Heat extraction efficiency
- Thermal fatigue reduction
Cooling Flow Analysis
Evaluates coolant performance in cooling channels: flow velocity, heat extraction rate, residence time, and pressure drop. Optimizes channel layout for maximum thermal management efficiency.
- Coolant velocity & turbulence
- Heat transfer coefficient mapping
- Residence time & temperature rise
- Channel geometry optimization
Part Ejection Simulation
Full mould stress simulation including solidification + stress analysis - predicts ejection forces, friction behavior, and potential part damage during the ejection stage. Critical for quality parts and ejector pin optimization.
- Full mould or solid shell stress model
- Contact pressure & friction coefficient modeling
- Static friction at extraction moment
- Shrinkage onto core & friction properties
- Ejector pin force & placement optimization
- Part distortion & damage risk assessment
Every critical simulation result from Cast-Designer: Flow, Solidification, Stress, and Micro-Structure.
Flow Simulation Results
17 outputs
