8 Best Casting Simulation Software

With the rapid development of computer technology, the simulation software of the casting process is also applied. The application of casting simulation technology is not limited to the simulation and analysis in the process of product development, and the process simulation of production and manufacturing also plays a pivotal role. That is, before casting, the simulation experiment is carried out on the computer for the established process. It can ensure the success of the process, design, and mold manufacturing. So, what is the commonly used casting software? We sorted out the commonly used casting simulation software list for you!

What is Casting Simulation Software?

Casting simulation software is a computer-aided engineering (CAE) tool used to model and analyze the metal casting process before actual production. It simulates how molten metal flows into molds, solidifies, and cools, helping engineers predict potential defects such as shrinkage, porosity, misruns, or cold shuts. By visualizing the entire casting process digitally, manufacturers can optimize mold design, gating systems, and process parameters to reduce trial-and-error, minimize waste, improve product quality, and save time and costs in metal casting production.

1.MAGMASOFT

MAGMAsoft is a comprehensive and effective simulation tool for improving casting quality, optimizing process conditions and greatly reducing casting costs. It supports the establishment of sound process conditions and the optimization of all casting materials and processes in casting. It is designed to predict casting quality by simulating filling, solidification and cooling in all casting production processes. In all casting processes, residual stress and deformation, as well as the stroke and property distribution of the microstructure can be effectively evaluated. Simulation can be used for virtual test planning while pursuing different quality and cost objectives.

Manufacturer: magma

Origin: Germany

2.FLOW-3D Cast

FLOW-3D cast provides a comprehensive casting solution with complete flow field and thermodynamic field. Through cooperation with customers in the metal casting industry, the casting process knowledge and simulation advantages are combined in the optimization process of casting and casting process, providing a complete simulation tool for the foundry, which can model all the casting processes common in modern foundry.

Manufacturer: flow Science

Origin: USA

3.ProCast

ProCAST provides many modules and engineering tools to meet the most challenging needs of the foundry industry. Based on powerful finite element analysis, it can predict severe distortion and residual stress, and can be used in semi-solid forming, core blowing process, centrifugal casting, lost foam casting, continuous casting and other special processes. Compared with the finite difference method (FDM), the numerical calculation method based on the finite element method (FEM) has greater flexibility and is especially suitable for simulating various physical phenomena in the forming process of complex castings.

Manufacturer: ESI

Origin: France

4.Huazhu CAE

Huazhu CAE takes the numerical simulation technology of the casting filling and solidification process as the core to carry out process analysis and quality prediction of the casting molding process, to assist the process personnel to complete the process optimization of the casting. It is an important tool for analyzing and optimizing the casting process. The software simulates the mold filling and solidification process of the casting and predicts the possible defects such as air entrainment, slag inclusion, sand flushing, insufficient pouring, cold shut, shrinkage cavity, and shrinkage porosity in the casting process.

Manufacturer: Huazhong University of Science and Technology

Origin: China

5.SolidThinking Click2Cast

SolidThinking click2cast is a casting simulation software that allows users to enhance and optimize their manufactured parts. Help users avoid typical casting defects, such as air retention, porosity, cold shooting, etc. due to simple and fast mold filling simulation. It provides an innovative user experience and avoids iteration between design and production.

Manufacturer: Altair

Origin: USA

6.NOVACAST

Novacast casting simulation system adopts advanced CVM control volume method computer numerical simulation technology. It is the best castingsoftware specially developed for analyzing, evaluating and optimizing casting process scheme. With the help of this software system, casting technicians can make computer simulation of the casting forming process under the existing scheme when designing the process scheme, display the changes of casting process temperature, mold filling speed, pressure and solidification time through the computer, and predict the possible defects.

Manufacturer: Novacast

Origin: Sweden

7.THERCAST

Thercast is a 3-D finite element software system used to simulate ingot casting and continuous casting of steel ingots and other metals. It reduces the time and cost of planning, optimizing, starting and running new casting processes or optimizing existing processes. Based on the non fixed 3-D finite element method, many thermodynamic and mechanical characteristics of casting process are fully integrated into a single model and a single algorithm set. This is the best casting software can greatly improve the accuracy in many aspects and provide the information needed to properly design or optimize the casting process.

Manufacturer: Transvalor

Origin: France

8.AnyCasting

AnyCasting is a new generation of advanced casting simulation software system based on Windows operating platform independently developed by AnyCasting company in Korea. It is a simulation system specially developed for various casting processes. It can be used to simulate the mold filling, heat conduction, solidification process and stress field of casting.

Manufacturer: AnyCasting

Origin: Korea

Best Sand Casting Simulation Software

The best sand casting simulation software includes industry leaders like MAGMASOFT, FLOW-3D CAST, ProCAST, and AnyCasting, which are widely used for their advanced modeling capabilities and accuracy. MAGMASOFT is highly regarded for its comprehensive process optimization and defect prediction tools. FLOW-3D CAST excels in simulating complex fluid flow and mold filling dynamics. ProCAST offers robust thermal, mechanical, and metallurgical simulation, making it ideal for predicting porosity and solidification issues. AnyCasting is user-friendly and cost-effective, suitable for small to mid-sized foundries. These tools help improve casting quality, reduce defects, and streamline production in sand casting operations.

Best Metal Casting Simulation

The best metal casting simulation software includes MAGMASOFT, ProCAST, FLOW-3D CAST, AnyCasting, and Simufact Casting, each known for their precision and comprehensive features. MAGMASOFT is a top-tier solution offering detailed insights into mold filling, solidification, and defect prediction across various casting methods. ProCAST stands out for its strong metallurgical modeling and support for a wide range of alloys. FLOW-3D CAST is favored for simulating complex fluid dynamics with high accuracy. AnyCasting provides fast and accessible simulations for small to medium manufacturers, while Simufact Casting offers seamless integration with manufacturing process chains. These tools help optimize designs, minimize trial-and-error, and ensure high-quality castings.

Best Investment Casting Simulation Software

The best investment casting simulation software includes MAGMASOFT, ProCAST, FLOW-3D CAST, and SOLIDCast, all known for their precision in handling the complex requirements of investment casting. MAGMASOFT is widely trusted for simulating intricate wax patterns and predicting shrinkage, porosity, and shell deformation. ProCAST offers robust thermal and microstructural analysis, making it ideal for high-precision aerospace and medical castings. FLOW-3D CAST excels in modeling fluid behavior during mold filling, especially for thin-walled and detailed components. SOLIDCast, paired with OPTICast, provides a cost-effective option for foundries needing solidification and gating system analysis. These tools improve casting quality, reduce defects, and optimize process parameters in precision casting workflows.

Best Solidification Simulation Software

The best solidification simulation software for metal casting includes MAGMASOFT, ProCAST, FLOW-3D CAST, and SOLIDCast, all of which specialize in predicting how molten metal solidifies within a mold. MAGMASOFT is renowned for its advanced solidification modeling, helping users minimize shrinkage defects and optimize cooling rates. ProCAST provides detailed thermal and metallurgical simulations, making it especially useful for complex alloys and high-integrity castings. FLOW-3D CAST offers high-resolution solidification analysis with accurate thermal flow coupling. SOLIDCast, often used with OPTICast, is a cost-effective yet powerful solution focused on solidification timing and defect prevention. These tools are essential for improving casting quality, reducing scrap, and achieving consistent results in foundry operations.

Best Casting Pattern Design Software

The best casting pattern design software includes Autodesk Fusion 360, SolidWorks, PTC Creo, and Siemens NX, which are powerful CAD platforms widely used in the casting industry to design precise and manufacturable patterns. These tools allow engineers to create complex 3D models with high accuracy, apply draft angles, shrinkage allowances, and simulate mold parting lines for easy pattern removal. Fusion 360 offers cloud collaboration and integrated CAM tools, while SolidWorks provides robust parametric modeling and mold design add-ons. PTC Creo and Siemens NX are ideal for complex assemblies and offer advanced surfacing and simulation features. These programs streamline the pattern-making process, reduce errors, and ensure compatibility with casting and machining operations.

Best Corrosion Simulation Software

The best corrosion simulation software includes COMSOL Multiphysics, Ansys Fluent, Delft3D, and CorrSim, each offering specialized tools to model and predict corrosion behavior in different environments. COMSOL Multiphysics stands out for its Electrochemistry and Corrosion modules, allowing detailed simulation of galvanic, pitting, and crevice corrosion in metals by coupling electrochemical reactions with fluid flow and material degradation. Ansys Fluent can simulate corrosion under fluid dynamics, such as erosion-corrosion or flow-accelerated corrosion. Delft3D is used for simulating corrosion in marine and coastal environments. CorrSim focuses on pipeline and structural integrity under corrosive conditions. These tools help engineers understand material lifespan, optimize protective coatings, and reduce failure risks in critical infrastructure.

Best Open Source Casting Simulation Software

Open-source casting simulation software options are limited compared to commercial tools, but OpenCast and Simulcasting are notable projects aimed at providing free, accessible casting simulation capabilities. OpenCast is a research-based tool that supports basic mold filling and solidification analysis using simplified models, making it suitable for academic or experimental use rather than industrial production. Some users also adapt open-source computational fluid dynamics (CFD) tools like OpenFOAM to simulate aspects of casting processes, such as metal flow and heat transfer, although this requires significant customization and expertise in physics modeling. While not as feature-rich as commercial software like MAGMASOFT or ProCAST, these open-source solutions offer a starting point for those with limited budgets or research-focused need.

8 Best Casting Simulation Software – Common Casting Software Album Recommended

What is Casting Simulation Software?