Metal Casting Design & Simulation (ESI QuikCast)
Our expert simulations help validate your mould and metal flow designs and improve manufacturability with clear, data-driven insights. Whether you need mould flow analysis, defect prediction, or process optimization, our advanced casting simulations ProCast . Contact us today to discuss what type if simulation you are interested in whether only a Solidification Model with feeder placements, or complete Fill/Feed systems.
Why Start with the Solidification Model in ProCAST?
If you’re new to metal casting simulation or just looking to keep costs lean, starting with the solidification model in ProCAST is a smart move. It’s cost-effective, faster to run, and still provides critical insights into key casting issues like shrinkage porosity, hot spots, and solidification time.
You don’t need full thermal-flow coupling right away—solidification-only analysis gives you a strong foundation to optimize gating, riser placement, and overall casting soundness, without the added complexity or price tag of full modules.
It’s the perfect balance of practicality and precision—ideal for feasibility studies, early-stage design, and fast iteration.
Benefits of ESI Simulation in Metal Casting
Utilizing ESI Group’s ProCAST simulation software offers a significant technical advantage in the design and optimization of metal casting processes { https://www.esi-group.com/customer-stories}. By integrating advanced physics-based modeling into the development cycle, simulation enables predictive insight that directly translates into improved quality, efficiency, and cost savings.
Key benefits include:
- ✅ Defect Prediction & Prevention
Identify and mitigate issues like shrinkage porosity, cold shuts, and hot spots before tooling or production begins. - ✅ Optimized Gating and Riser Design
Virtually test and refine gating/riser systems to ensure directional solidification and minimal waste—reducing rework and trial runs. - ✅ Material and Process Versatility
Simulate a wide range of alloys, mold materials, and casting methods (gravity, HPDC, investment casting, etc.) with high accuracy. - ✅ Cost & Time Savings
Eliminate costly tooling iterations and reduce lead times by addressing problems in the digital domain first. - ✅ Improved Yield and Consistency
Enhance casting soundness and repeatability through process-controlled design iterations and thermal mapping. - ✅ Documentation & Transparency
Simulation results provide visual, quantitative data that support decision-making and can be included in customer reports, quality documentation, and continuous improvement programs.