Cast-Designer V7.9 is a comprehensive Computer-Aided Engineering (CAE) software suite specifically developed for the metal casting industry. It streamlines the entire casting development workflow, starting from the initial part design (CAD) through the critical stages of gating and riser system design, and concluding with high-fidelity mold filling and solidification simulation. By predicting potential defects like shrinkage porosity, cold shuts, and misruns early in the design phase, Cast-Designer empowers foundry engineers and product designers to achieve high-quality castings with fewer physical trials, reducing scrap rates and accelerating time to market.

 Core Functional Capabilities of Cast-Designer V7.9

• Intelligent Gating & Riser System Design (PRE-CAST)
  Automatically generate and optimize feed systems. This unique module uses expert knowledge and heuristic rules to propose initial gating and risering layouts based on the part geometry and casting method (sand, investment, die casting), providing a excellent starting point that drastically reduces manual design time.

• Integrated 3D Flow & Solidification Simulation (CAST-DESIGNER)
  Perform coupled mold filling and solidification analysis. The software uses advanced Computational Fluid Dynamics (CFD) to simulate the complete pouring process, tracking fluid flow, heat transfer, and solidification to identify thermal hotspots, predict shrinkage defects, and evaluate the effectiveness of the feeding system.

• Advanced Defect Prediction & Visualization
  Identify and diagnose quality issues virtually. The software provides clear visual indicators for predicted defects such as shrinkage porosity (using the Niyama criterion or fractional solid model), air entrapment, and cold flows, allowing engineers to make informed design changes before tooling is manufactured.

• Process Parameter Optimization & DOE
  Systematically improve your process. Cast-Designer includes Design of Experiments (DOE) tools to automate the study of multiple variables (like pouring temperature, gate size, chill placement) and identify the optimal parameter set for yield, quality, and cycle time.

The Cast-Designer Advantage for Foundries

Many simulation tools focus only on analysis after the process is designed. Cast-Designer V7.9 differentiates itself by actively assisting in the design of the casting process itself. Its integrated approach—from intelligent initial layout to detailed validation—closes the loop between design intent and manufacturability. For foundries producing complex castings for automotive, aerospace, and heavy machinery, this software is a powerful ally that reduces dependency on veteran experience, standardizes best practices, and provides a scientific foundation for producing defect-free castings consistently and efficiently.