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Cast-Designer for Investment Casting

Cast-Designer for Gravity casting supports Investment casting process.

For high temperature process like investment casting, the heat radiation must be considered in the simulation. The affection of shell and enclosure is important in radiation calculation, it must be modelled. View factor and shadow factor may change the solidification and porosity results.

ENCLOSURE, RADIATION & VIEW/SHADOW FACTOR

Cast-Designer for Investment Casting

Cast-Designer revolutionizes investment casting design with its upfront simulation technology that combines expert systems with advanced CAE analysis. This powerful integration enables engineers to optimize fluid flow, heat transfer, and solidification parameters during the earliest design phases, ensuring right-first-time engineering decisions.

Transform Your Design Process

By identifying potential defects and evaluating gating systems before production, Cast-Designer significantly reduces development time and costs. Its intuitive interface allows both novice and experienced engineers to achieve reliable results quickly, accelerating your time-to-market.

Key Benefits

  • Early validation: Detect flow and solidification issues in the design phase to avoid costly revisions
  • Rapid optimization: Evaluate multiple gating system alternatives in minutes rather than days
  • Intelligent analysis: AI-enhanced insights guide engineers to optimal solutions
  • Collaborative workflow: Clear visualization tools improve communication with customers and teams
  • Knowledge building: Create a growing database of proven design solutions
  • Accessible technology: Short learning curve delivers quick ROI

Why It Matters

In today's competitive environment, Cast-Designer provides the technological edge to:

  • Reduce simulation setup time by up to 80% compared to traditional methods
  • Cut development costs by identifying problems before tooling begins
  • Improve casting quality and consistency through data-driven design
  • Accelerate product launches with faster iteration cycles
 
Geo Designer Capabilities
Geo Designer Hotspot

Advanced Gating System Design for Investment Casting

Gate System Advisor

Cast-Designer's expert system combines KBE technology with five decades of investment casting expertise to guide designers through optimal gating system development.

The intelligent Gate System Advisor calculates precise filling times and inner gate section areas based on:

  • Casting weight/volume
  • Feature thickness
  • Material properties

Designers can then fine-tune runner and sprue dimensions with real-time feedback.

Main Tree & Runner Design

Cast-Designer is the industry's only comprehensive solution for investment casting system design, offering unparalleled parametric control over complex configurations.

Complete System Design Capabilities

  • Full parametric control: Design risers, inner gates, runners, and chills with precision
  • Pre-built templates: Access industry-proven main tree configurations
  • Custom templates: Import/export designs for consistent quality
  • Adaptive technology: Handles even the most complex casting systems
Geo Designer Capabilities
Geo Designer Hotspot

SMART Designer for Runner Systems

Our innovative SMART Designer function leverages decades of industrial experience to optimize production yield while maintaining casting quality.

Intelligent Layout Automation

The system automatically generates optimal runner designs by analyzing:

  • Total casting weight
  • Part geometry dimensions
  • Layout boundary requirements

Key innovation: The system uses main runners and pouring cups to compensate for metal shrinkage during solidification, addressing both filling and porosity concerns simultaneously.

Radiation, View and Shadow Factor

  • For high temperature process like investment casting, the heat radiation must be taken into account.
  • The effect of shell and enclosure is important in radiation calculation, Cast Designer has tools to include these into the model setup easily
  • View factor and shadow factor may change the solidification result. It can be specified in the Cast Designer Model Setup.
Geo Designer Capabilities
Geo Designer Hotspot

Regions with dewax problem

DeWax Analysis

Dewax function checks the casting geometry and identifies potential regions which could cause dewax issues. A casting system with good dewax design can improve the product quality and save energy..

Investment Casting Process Optimization

Casting Part Analysis
1

Part Analysis

Analyze the casting part, check the MDI & HDI, define the position and size of inner gate.

Main Tree Selection
2

Smart Tree Selection

Select the main tree in smart design tools based on KBE, considering weight and numbers of casting parts.

Tree Generation
3

Tree Generation

Generate the main tree and part layout with optimized configuration for production.

Dewax Checking
4

Dewax Process

Perform dewax checking and make necessary adjustments to the design.

Shell Generation
5

Shell Preparation

Shell generation and CAE analysis modeling for quality assurance.

Flow Simulation
6

Flow Simulation

CAE simulation result of metal flow during the casting process.

Porosity Analysis
7

Porosity Analysis

CAE simulation result showing shrinkage porosity distribution.

Original Design
8

Original Design

The old design with serious porosity problems requiring improvement.

Revised Design
9

Revised Design

The optimized design saves 38% yield ratio with significantly reduced shrinkage porosity.

38% Yield Improvement

C3P Cast-Designer Investment Casting Software

Advanced flow, solidification and stress simulation for lost wax investment casting. Optimize gating system, shell design, and process parameters. Authorized Master Distributor in India.

🌊 Flow Simulation Features

  • ✓ Metal Flow Pattern Analysis
  • ✓ Filling Defect Prediction
  • ✓ Air Entrapment Detection
  • ✓ Temperature Distribution Mapping
  • ✓ Oxide Film Formation Prediction
  • ✓ Velocity Profile Visualization
  • ✓ Misrun & Cold Shut Prevention

❄️ Solidification Analysis Features

  • ✓ Hot Spot Identification
  • ✓ Shrinkage Porosity Prediction
  • ✓ Cooling Curve Analysis
  • ✓ Directional Solidification
  • ✓ Grain Structure Prediction
  • ✓ Feeder & Riser Effectiveness
  • ✓ Chill Design Optimization

⚡ Stress Simulation Features

  • ✓ Hot Tear Prediction
  • ✓ Residual Stress Analysis
  • ✓ Casting Distortion Simulation
  • ✓ Thermal Stress Distribution
  • ✓ Cracking Risk Assessment
  • ✓ Stress Relief Recommendations

🔄 Investment Casting Process Simulation

Wax Injection Shell Building Dewaxing Preheating Pouring Solidification Cooling Knockout

🔩 Investment Casting Alloys Supported

Aluminum Alloys Carbon Steel Stainless Steel (304, 316, 17-4PH) Cobalt Chrome Nickel Superalloys (Inconel, Hastelloy) Titanium Alloys Copper Alloys Tool Steel

✈️ Investment Casting Applications

Aerospace Turbine Blades Medical Implants Automotive Components Jewelry & Art Casting Industrial Valves & Pumps Defense Components Marine Hardware Orthopedic Implants

⚠️ Investment Casting Defects Predicted

Porosity Shrinkage Cavities Hot Tears Cold Shuts Misruns Cracks Distortion Inclusions

📧 nageswarababu.k@nestechglobal.com | 📞 +91-8056372404

🏆 Authorized Master Distributor in India for C3P Cast-Designer Software

Request a demo for Cast-Designer Investment Casting Software

NESTech Services and Products

Why Choose NESTech as your CAD CAE Partner?

+ Drawings Created
+ Simulations done
+ Team Members
+ Years of Experience
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RICH EXPERIENCE

We bring 25+ years of rich experience to every project, ensuring exceptional results and unparalleled reliability.

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ON-TIME DELIVERY

With meticulous planning, streamlined processes, and a dedicated team, we ensure that every project is completed promptly and efficiently

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EXCELLENT COLLABORATION

We foster a culture of teamwork, communication, and mutual respect, ensuring that every project benefits from the diverse perspectives and expertise of our team members.

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COST EFFECTIVENESS

With a multitude of projects Completed and catering to various industries, we have demonstrated excellent business results at lower cost with our domain expertise.

Some of the Cast-Designer Software Customers