CAST-DESIGNER SOFTWARE OVERVIEW

Cast-Designer provides unique Quick Design tool, Accurate CFD based simulation and AI Optimization Tools.

QUICK DESIGN TOOLS

C3P Cast-Designer provides industry's unique quick design, validation and optimization tools to aid engineers during design stage, which saves time and cost.

Design For Manufacturing
Gating Design Wizards
QuickCast Flow Simulation
QuickCast Auto Optimization
SmartRunner Design
FastCooling Simulation
SmartCooling System Design
Media Flow in Cooling Channels

ACCURATE SIMULATION

Cast-Designer provides most accurate simulation results, achieved through innovative latest technology.

Dual Solvers: CFD And FEM
Flow And Solidification
Stress And Warpage
HPDC, Giga, Thixo
Gravity Casting Processes
Full-mould Cyclic Simulation
Core Gas – Core Blowing
Micro-structure Simulation
Grain-structure Growth Simulation

AI OPTIMIZATION

Save time, reduce costs, boost production rate, prevent defects and improve quality with Cast-Designer's AI Optimization Tools.

Production Optimization
Gating Optimization
Warpage Compensation
Yield Improvement
Design Of Experiments
Heat-treatment Simulation
Part Ejection Simulation
Die Spray Optimization
Mould-Casting Gap Simulation

Cast-Designer Overview

Supported Casting Process

High pressure die casting.
Low pressure die casting.
Semi-solid casting.
Gravity sand casting.
Gravity die casting.
Gravity Casting for DISA
Gravity tilt pouring. /Tilt Casting
Investment casting.
Continuous casting.
Centrifugal casting.
Lost-foam casting.
Vacuum casting.
Liquid stamping.
Ladling operations
Core bowling
Wax injection

Some of the Cast Designer CPI Results

Material Flow
Flow Temperature
Flow Tracelines
Solidification
Shrinkage Porosity
Air Entrapment
Velocity
Pressure
Liquid Fraction
Solid Fraction
Temperature Distribution
Stress Distortion
Compensation Prediction for Distortion
Flow Length
Material Age
Oxides
Flow Vs Gate in color
Cooling Rate
Mould Temperature
Cyclic Analysis
Full-Couple Analysis (Thermal+Fluid+Mechanical)
Solidification Time
Filling Time
Maximum Pressure
Hot Tearing
Stress
Strain
SDF Stength
Pin Squeeze
Micro-Structure Analysis
And many more....

Material Database

Cast Designer has more than 400 industry standard materials in the database.

Casting Material

Cast iron: grey, SGI, CGI
White cast iron
Ni-Resist D2, D5
SiMo
Carbon steels
Stainless steels
Copper alloys
AlSi7 up to AlSi12
Mg-alloys
Zn-alloys

Mould materials:

Green sand
Dry sand
Chemical sand
Cr sand
Zr sand
Special sand
Silicon carbide
Graphite
Die
Insulation
Exothermic Sleeves
Filter

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.