Casting Simulation Software: Reduce Casting Defects
TL;DR: Casting simulation software predicts mould filling and solidification before pouring, so defects are fixed on screen, not on the shop floor. Tools like MAGMASOFT and ProCAST cut porosity, shrinkage, and scrap in investment casting.
Casting simulation software models how molten metal fills a mould and freezes. For aerospace and defence, casting simulation software means fewer defects, less scrap, and faster proving of new parts. It pairs perfectly with our investment casting process.
What Is Casting Simulation Software?
Casting simulation software is a virtual model of the casting process. It simulates mould filling and solidification to predict defects such as porosity and shrinkage before any metal is poured. This lets engineers correct problems early, long before any tooling is cut. See this reference.
Solidification Simulation Casting Explained
Solidification simulation casting shows how a part freezes after the mould is filled. By mapping cooling, solidification simulation casting reveals hotspots that would trap shrinkage porosity in the final part. Fixing those hotspots on screen is far cheaper than scrapping finished parts.
What solidification simulation casting predicts:
- Thermal hotspots that solidify last and trap shrinkage.
- Shrinkage porosity locations before pouring metal.
- Cooling and solidification rates across the part.
- Whether risers can feed every heavy section.
- Residual stress and distortion risk after cooling.
How Casting Simulation Reduces Defects
Casting simulation reduces defects by testing the mould design virtually. Engineers adjust gates, runners, and risers on screen until the model is sound, so the first real casting is right the first time.
How casting simulation reduces defects:
- Optimises gating so metal fills smoothly without turbulence.
- Predicts shrinkage so risers are sized and placed correctly.
- Confirms feeding reaches every heavy section of the part.
- Cuts costly physical trials and tooling rework.
- Improves first-time-right yield and reduces scrap.
MAGMASOFT and ProCAST Simulation Tools
Two tools lead the industry. MAGMASOFT casting simulation is known for solidification and defect prediction, while ProCAST mold filling simulation excels at modelling how metal flows into complex investment castings.
- MAGMASOFT casting simulation for solidification and porosity.
- ProCAST mold filling simulation for accurate flow modelling.
- Mould-filling analysis to prevent cold shuts and misruns.
- The software that simulates investment casting solidification end to end.
Casting Simulation Software at Uni Tritech
Uni Tritech is a NADCAP-certified, AS9100D foundry approved by Airbus and Collins Aerospace. We use casting simulation software to prove out gating and feeding, backed by in-house NDT and laboratory services.
- Simulation-led gating and riser design for every new part.
- Vacuum induction melting for clean aerospace alloys.
- NADCAP-accredited NDT verifies internal soundness.
- AS9100D quality system, Airbus and Collins approved.
Frequently Asked Questions
Casting simulation reduces defects by modelling mould filling and solidification virtually. Engineers fix turbulence, shrinkage, and feeding problems on screen, so the first physical casting is sound and scrap is minimised.
MAGMASOFT and ProCAST are the leading tools. MAGMASOFT casting simulation focuses on solidification and porosity, while ProCAST mold filling simulation models how metal flows into the mould.
Casting simulation software is used to predict defects, optimise gating and risers, and reduce trials before pouring, which improves quality and first-time-right yield in investment casting.
Yes. Solidification simulation casting and mould-filling analysis are widely used for investment casting to prevent porosity, shrinkage, cold shuts, and misruns in complex parts.
Yes. Uni Tritech uses casting simulation software to model your part, optimise gating and feeding, and confirm soundness before cutting tooling or pouring metal.
Want castings proven by casting simulation software before pouring? Contact Uni Tritech to discuss your components.
Looking for defect-free castings backed by simulation?
Uni Tritech uses casting simulation software to deliver right-first-time aerospace castings. Talk to us about your components today.