Simulate the Complete Casting Process for Defect-Free Parts Every Time With a Single Tool

Your first off-tool parts are finally available, only for you to realize they contain pinholes, shrinkage, or hot spots. With your deadline staring you in the face, you can either ship the parts and undoubtedly deal with an unhappy customer or go back to the design stage and try to identify the problem, correct it, and hope it is finally free from defects. And because the trial period in the casting development schedule is underestimated, it is imperative to get your gating design to be robust against process variations before arriving at the testing phase.

Simulation allows for virtual testing early on in the development stage. Accurate prediction and quantification of defects and process design are imperative in order to ‘get it right’ during production trials.

With ESI ProCAST you can cast your parts right the first time, every time –meeting your deadlines and never wasting money on scrap parts or late redesigns. For decades, customers have relied upon ProCAST as their go-to tool for the casting basics – filling, solidification, and porosity prediction. With its finite element technology, it also predicts complex issues like deformations and residual stresses and comprehensively addresses most castable alloys and most casting processes like sand castings, die castings, investment castings, and multiple variants associated with these processes.

Benefits of ProCAST

  • Predict, analyze, measure and quantify the most common casting defects in the earliest stages of design (E.g., Volume of porosity measured, as in Tomography)
  • Simulate the entire process – from furnace to final casting to capturing and tracking all physics. (E.g., Start with the dosing of the sleeve to predict early air entrainment)
  • Comprehensively compute radiation with view factors to account for the shadowing effects, common in high-temperature investment castings
  • Compute stresses through the process, both during solidification inside the mold and cooling outside the mold, predict final distortions and evaluate them easily with 3D scanner measurements
  • Predict grain structure including equiaxed & single crystal, microstructure, and mechanical properties
  • Automatically determine the casting part's best process window to reach the final quality goal through DOE, Optimization & Process Robustness analysis

The cooperation with ESI within the BOOST project was very pleasant and professional. With ESI’s know-how and the advanced simulation capabilities of ProCAST it prooved possible to identify the root causes of complex casting defects and to point out ways how to improve those.

Gerhard Huber
Gerhard Huber – Simulation Expert, Nemak Linz GmbH


Casting Simulation Webcast Now Available On-Demand


Interested in hearing how ProCAST is essential to ensure getting casting parts right the first time, meeting deadlines, and cutting costs on scrap parts or late redesigns? With its finite element technology, you can predict complex issues like deformations and residual stresses and comprehensively address most castable alloys and most casting processes like sand castings, die castings, investment castings, and multiple variants associated with these processes.

During an exclusive digital digital event, casting engineers from Kovolis Hedvikov, MCS, and Azterlan shared how they predict, analyze, measure, and avoid casting defects in the earliest stages of design.


Watch on Demand

Sand Castings

The key to success in a sand casting foundry is optimizing the gating system and eliminating the risk of shrinkage porosity. ESI’s ProCAST allows comprehensive modeling of any sand casting process, including high-pressure molding lines. It enables users to study the effects of feeder locations, filters, chills, insulation & exothermic sleeves on the casting process and quality. Different aspects, including filling, solidification & residual stresses can also be studied.

The standard porosity model of ProCAST also accounts for the effect of the expansion of cast iron during solidification and mold rigidity, which allows or restricts this expansion. A more comprehensive approach consists of running coupled, thermal microstructure and porosity calculations, including inoculation. The microstructure solver computes the evolution of different phases and predicts local density variations, which provide more realistic porosity results. Specific microstructure models exist for different cast irons: GI, SGI, CGI, and Ni-Resist.

Die Castings

Reproduce shop floor conditions by performing several production cycles and obtaining steady-state die temperatures, thereby studying filling, solidification, intensification pressure effect, cooling channel design & process parameters optimization.

Die Casting machine is integrated inside ProCAST, enabling a real-time piston control and, hence, accurate selection of the right machine. Vacuum process, gas porosity – due to undissolved hydrogen, stresses in casting, stress release on die removal & part ejection, and die life – can all be predicted to reduce manufacturing costs and assess in-service part performance. Specific needs including squeeze, semi-solid materials, shot sleeve modeling for cold chamber, gooseneck modeling for hot chamber machines, and riser tube modeling in low pressure die castings can be attained. Gravity die casting, including tilt pouring processes, can be modeled, and ProCAST enables free definition of the axis and velocity of rotation.

Investment Castings

ProCAST can automatically generate a mesh representing the shell mold suitable for Investment Castings & Shell Molding processes. Furthermore, it has dedicated features to address the specific needs of investment casting foundries, like allowing for non-uniform shell thickness to be blended and multiple shell layers to be created. Also, radiation with view factors, including shadowing effects critical for high-temperature alloys, are considered.


ESI’s QuikCAST is fully integrated into ESI ProCAST and is available for use in Visual-Environment. QuikCAST is a fast and efficient solution for complete process evaluation. It meets industrial needs, delivering rapid and realistic predictions, allowing foundrymen to simulate the entire casting process from filling to solidification, including defects prediction.

QuikCAST Meets Industrial Needs

Cutting costs and reducing time to market are two of the most pressing problems for the casting industry. QuikCAST is designed to help the user achieve these goals. You can use it early for mold & process development as well as for cast part quality assessment.

QuikCAST accounts for air back pressure, filters, mold roughness, thermal exchanges, die coatings, and gravity to accurately simulate most casting processes ranging from gravity sand casting to high and low pressure die casting, including core blowing.

More Casting Applications & Cast Defects:

  • Residual Stress & Distortion
  • Microstructure & Heat Treatment
  • Advanced Porosity Model
  • Grain Structure
  • Process Optimization
  • Continuous Casting
  • Centrifugal Casting
  • Lost Foam

Smooth integration of ProCAST for casting simulation into your existing processes  

Current product development and manufacturing processes use different methodologies to bring the dies to production. Together with you we define a structured deployment of ProCAST into your existing engineering workflows thereby ensuring full integration and enable a comprehensive die casting process validation. ESI’s customer experience team for casting simulation accompanies you through the complete implementation process from software evaluation and building of simulation models throught to the interpretation of the simulation results  and training in efficient work with ProCAST.

  • Training and first-class software support to help customers tackle all casting simulation challenges
  • Access to a database of Tips & Tricks and Technical Papers in our customer portal myESI
  • Knowledge exchange with global ProCAST community and attend our advanced technical events such as our annual Solidification Course

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