2. CAST-DESIGNERTM
What is Cast-Designer ？
Cast-Designer is a useful and powerful system
to support designers and engineers make
system design and upfront analysis in an
express way for casting process.
• DFM analysis to support casting part design and
manufacturing process design
• Expect system for casting system design in tens mins to
half hour ；
• Special Upfront analysis technology for metal filling and
solidification analysis based on the last FEM technology,
the lead time is 2 to 3 times faster compared with
tradition CAE tools includes modeling and simulation ；
• Standalone software system based on Open CASCADE
technology or fully integrated to the common MCAD
system.
• Developed by C3P Software with close collaboration with
world top level industrial partners, research institutes
and universities.
3. CAST-DESIGNERTM
• Quality by Design is
one of the most
misunderstood and
misused tools
available to industrials.
• ~ 5% design lead time
to solve at least 80%
quality problems.
• Quality of productions
was not depended on
checking, not only
depended on the
produce process, but
also mainly depended
on design process.
We special focus on ‘Design’ and ‘Designer’
Product Designer
• No casting background
• Focus the function of the product
Casting
performance
of this
product?
Geo-Designer
4. CAST-DESIGNERTM
• Quality by Design is
one of the most
misunderstood and
misused tools
available to industrials.
• ~ 5% design lead time
to solve at least 80%
quality problems.
• Quality of productions
was not depended on
checking, not only
depended on the
produce process, but
also mainly depended
on design process.
We special focus on ‘Design’ and ‘Designer’
Die design
Engineer
Product Designer
• No casting background
• Focus the function of the product
Casting
performance
of this
product?
•Die Designer
•Specialists in casting
field (process and
materials)
•No CAE experience
Which design
is best?
5. CAST-DESIGNERTM
• Quality by Design is
one of the most
misunderstood and
misused tools
available to industrials.
• ~ 5% design lead time
to solve at least 80%
quality problems.
• Quality of productions
was not depended on
checking, not only
depended on the
produce process, but
also mainly depended
on design process.
We special focus on ‘Design’ and ‘Designer’
CAE
Specialists
Die design
Engineer
Product Designer
• No casting background
• Focus the function of the product
Casting
performance
of this
product?
•Die Designer
•Specialists in casting
field (process and
materials)
•No CAE experience
Which design
is best?
•Practical knowledge in
casting technology
•Advanced CAD
capabilities
•Modeling experience
•Specialists of CAE
6. CAST-DESIGNERTM
• Quality by Design is
one of the most
misunderstood and
misused tools
available to industrials.
• ~ 5% design lead time
to solve at least 80%
quality problems.
• Quality of productions
was not depended on
checking, not only
depended on the
produce process, but
also mainly depended
on design process.
We special focus on ‘Design’ and ‘Designer’
CAE
Specialists
Die design
Engineer
Product Designer
• No casting background
• Focus the function of the product
Casting
performance
of this
product?
•Die Designer
•Specialists in casting
field (process and
materials)
•No CAE experience
Which design
is best?
•Practical knowledge in
casting technology
•Advanced CAD
capabilities
•Modeling experience
•Specialists of CAE
Cast-Designer CPI
Cast-Designer Basic
Geo-Designer
8. CAST-DESIGNERTM
What is Geo-Designer? (I)
• Geo-Designer is a powerful upfront Design for Manufacturing (DFM) tools
for designers and manufacturing engineers with innovative technology.
• It accelerates the design process for functions, manufacturability, enabling
designs to move to production better and faster.
• Geo-Designer is powerful, flexible, fast and easy to use and provides
savings in downstream costs by quality improvement at the design stage.
• Geo-Designer offer a new method to study the part geometry in 3D Iso-
surface with flexible transparently, it is similar the x-ray and CT method in
industrial.
• Geo-Designer can analysis the product thickness, draft angle or undercut
and fillet radius. Ray method and the Mass Distribution Index (MDI) are
supported for geometry analysis.
9. CAST-DESIGNERTM
What is Geo-Designer? (II)
• Geo-Designer can analysis the heat transfer and distribution for the
casting process. The Heat Distribution Index (HDI) analysis is much faster
and simple than any numerical simulation method.
• Geo-Designer can make slider analysis to support mould design.
• Geo-Designer can make ejection force analysis for both value and
distribution to support ejection pin design.
• Geo-Designer can make core checking and design for gravity casting part.
10. CAST-DESIGNERTM
Geo-Designer could be used for …
Mass distribution
Wall thickness
Draft Checking
Fillet Radius
Core checking
Cooling rate
Riser & Gate
Heat distribution
Slider Checking Ejection Force
Chill Design
11. CAST-DESIGNERTM
Part Analysis for Gravity Casting
Ray thickness of casting part, used for thin wall analysis usually
Section cut of thickness
and Mass Distribution
Index
12. CAST-DESIGNERTM
Concept of Heat Distribution Index (HDI)
AE
CB
F G
In HDI calculation, the system will also consider the heat
affection of the around media. For example, heat affection by
the same part or the riser for gravity casting, it is also possible
to consider the different material and heat type, such as chill to
speed up cooling, insulates to keep the heat to cool down
slowly.
If we check it in MDI, the result of region E should be same as
the other side of the plate A, such as the left end or the right
end. But for heat transfer, plate B and C must affect the heat
distribution of region E, such as the region F and G should be
more difficult to cool down.
MDI=15 MDI=20HDI=15 HDI=20
14. CAST-DESIGNERTM
Using HDI for riser design (2)
Read in the riser, chill and
gating system one by one.
Assign different material
properties to riser, gating, chill
and insulator.
15. CAST-DESIGNERTM
Using HDI for riser design (3)
Generate the Geo-Designer
model and make HDI analysis.
The last picture show the result
of HDI =15. the affection of the
chill to heat distribution is clear
(the red arrow).
16. CAST-DESIGNERTM
Using HDI for riser design (4)
We continue check the HDI in
higher value, such as 20, 25,
30 and 35.
The region with arrow is high
risk for shrinkage porosity after
the casting process. So the
user can adjust the size and
locations of the risers to
achieve a better result.
17. CAST-DESIGNERTM
Application: Geo-Designer for Engine Block
Geo-Designer could be used to check the basic
information of the part, to guide the product design and
provide more detail information for manufacturing process
design. The information includes,
General thickness of the part
Section thickness of the part
Part information such as volume, mass, surface area,
geometry modules, projection area in X/Y/Z direction
Part Checking:
18. CAST-DESIGNERTM
Geo-Designer for Engine Block: casting checking
Geo-Designer
provides function
for slider checking.
The red color
region must use
slider to help eject
the part after
casting. This
information is very
useful for die
designer.
Slide checking: Core checking:
Sand core checking is
very important for the
complex part, such as
engine block. It should
be useful to check the
weak sections of the
core at product design
stage.
19. CAST-DESIGNERTM
Geo-Designer for Engine Block: Riser design
Geo-Designer provides a
quick analysis of the
thicker wall zone and such
information could be used
for riser & feeder design.
Region volume and mass
in higher HDI could be
used for riser size design
after consider the riser
effectively.
20. CAST-DESIGNERTM
Geo-Designer for Engine Block: Riser design
Build in riser design
functions to provide
online riser design
capability and check
it immediately.
Support box, cylinder,
cone and ball design.
Support STL import
for addition fuse and
substrate for more
complex geometry.
22. CAST-DESIGNERTM
Turn your design concept to 3D data in a quick way
1
2
It is really hard for me to make a clear
decision before I have a detail 3D casting
system…
No problem! Cast-Designer
can do that in a few minutes …
23. CAST-DESIGNERTM
Cast-Designer for Casting System Design
Cast-Designer BASIC is an efficient
3D CAD tools with expert system
special for HPDC
Expert
Power
Platform
An Expert System for Gravity Casting System design to
help designer and engineer make a reasonable casting
system in a quick way
Designer application Includes riser, feeder, gating
system , chill, well and cooling system
Standard alone software based on last Open CASCADE
technology or fully integrated to common MCAD
system, such as Pro-E, UG NX, SolidWorks etc
Usage
Data
Learning
The design approach is much faster and simple compared
with tradition CAD system and fully parametric
Standard and special data exchanger for 3D CAD
system and CAE system
Short learning curve and enhance company design
ability shortly
Cast-Designer BASIC is an efficient 3D CAD
tools with expert system for Gravity Casting
25. CAST-DESIGNERTM
Cast-Designer: Riser & Feeder design
Riser & Feeder Design
Build in wizards or calculators to guide the
user swiftly towards the optimized design
of a feeding and gating system
Riser Design Rule:
• Time condition: Solidification
• Volume condition: predict the delivered
volume of open or blind riser or
isothermal sleeve
• Distance condition: feeding
26. CAST-DESIGNERTM
Gating System Design Advisor
Casting Design Advisor
metal, mass,
quality requirement
Casting Volume
Riser & Feeder
Filling Time
Inner Gate
Help solve the
solidification problems
Casting alloy, Casting
part geometry
Nbs, section area
(Design finished)
Fine turning
Sprue runner
Runner
Speed Up Ratio
Nbs & section area,
shape parameters
Design runner, Nbs &
section area
Increase ratio of
pouring system/Spure:
Runner : inner gate
27. CAST-DESIGNERTM
1
5
43
2
Cast-Designer: Runner design
Gate & Runner Design
Build in wizards or online help to guide the user swiftly towards
the optimized design
• Full casting system design (inner gate, runner, Sprue runner,
chill, well, cooling system …)
• Very similar interface for all design components
• Multi-objects support, Multi-plan support
• Full 3D model, support draft design concept
• What You See, What You Get work style (WYSWYG)
• Flexible coordinate adjustment, flexible objects operation
• Data template concept, import and export data template.
29. CAST-DESIGNERTM
One button design for gravity casting gating system
• A new approach for gating system design for
gravity casting process. It is very suitable for
concept design after get the part.
• Based on pre-defined gating system template,
more than 20 pre-defined templates inside the
software package.
• Support CDGL (Cast-Designer Gating System
design Language) to expand the gating system
template by user
• Design lead time can be 5 to 10 times faster than
the standard design method in Cast-Designer, and
tens times faster than CAD.
• The design result by One Button Design could be
transferred to the standard design wizard directly,
for any modification.
30. CAST-DESIGNERTM
One button design for gravity casting gating system
Pre-defined template in Cast-Designer
With a rich gating system library for common gravity casting and investment casting.
• Very easy to use, set the first gating system within 5 minutes.
31. CAST-DESIGNERTM
One button design for gravity casting gating system
One button gating system design procedure
Full parametric design, very easy to adjust the shape and dimension.
• Main parameters to control the major dimension and shape minor parameter to control the details.
32. CAST-DESIGNERTM
One button design for gravity casting gating system
One button gating system design examples
Put the concept to design quickly. Possible to do final tuning for detail shape and dimension in Cast-Designer wizard.
34. CAST-DESIGNERTM
1 2 3
Thanks Cast-Designer to provide a fast and
flexible way in casting system design, but I
still have another question…
Which one is the best design?
Why Cast-Designer CPI?
No problem!
Cast-Designer CPI can
do that …
35. CAST-DESIGNERTM
What is Cast-Designer CPI (Casting process insight)
Analysis
Evaluation
Analysis the metal filling and solidification process
Provide an accurate, express and flexible method for
casting system evaluation, select the ‘right’ design
Express
Innovation
Express part and wall thickness analysis
Innovation technology compared with tradition CAE
method, upfront analysis, accurate, flexible and no
limitation.
Cast-Designer CPI is a powerful tool integrated in
Cast-Designer system based on the last CAE technology
36. CAST-DESIGNERTM
What is Cast-Designer CPI (Casting process insight)
No requirement for any CAE
knowledge, easy learning
Start from CAD or STL, auto repairing
and healing
High-End technology to provide really virtual
result in a short time
Filling: metal filling process, air entrapment,
velocity, vector, pressure
Solidification: Temperature, liquid/solid fraction
CPI is the sole
really practical
method on the
marketing today
to support
casting design
40. CAST-DESIGNERTM
Time
Ease of Use
Easy
Advance
Middle
~2 Hours 2 days1 day
CAST-DESIGNER
CPI
ProCAST
MAGMA
FLOW3D
ANYCAST
NOVACAST
CAST
ENGINEER
CAE Simulation
Upfront Analysis
Ease of Use vs Express Upfront Analysis
Start point Modeling time Analysis time Result accuracy
41. CAST-DESIGNERTM
Cast-Designer CPI Flow Chart
CAD Data
• Start from 3D casting, support almost
CAD system, such as Catia, UG, Pro-
E, Solidworks and AutoCAD
• Standard CAD import and export:
STEP, IGES, BREP, DXF, STL
• Extra converter to support Catia, UG,
Pro-E, Solidworks data directly
• Support many CAE mesh format (STL,
UNV, Ansys, Nastran etc.)
• Build in OpenCASCADE CAD kernel
with 3D capability
• Powerful CAD clean, healing &
processing functions
42. CAST-DESIGNERTM
Cast-Designer CPI Flow Chart
CAD Data
Gate System
• Using Cast-Designer to design 3D riser,
chills, gating system and cooling
system;
• Expert system for gravity casting
design with industrial validation widely
• Natural design workflow, full parameter
control, flexible, powerful and easily
• Build in industrial knowledge,
experience and know-how
• Support data template and customized
template
43. CAST-DESIGNERTM
Cast-Designer CPI Flow Chart
CAD Data
Gate System
CPI Meshing• Fully automatically voxel meshing, no
CAE knowledge required
• Very fast and robust, flexible control the
voxel size in different direction
• Support multi domain, no Boolean
operation required of CAD before voxel
meshing
• Original data could be CAD or mesh or
mixed CAD and mesh
• Special treatment for CAD or mesh
defects, such as geometry gap, overlay,
intersection or unclose.
• Special treatment for tin dimension region
to avoid huge model or feature lose.
44. CAST-DESIGNERTM
Cast-Designer CPI Flow Chart
CAD Data
Gate System
CPI Meshing
CPI Setup
• Setup casting process, boundary condition and control parameters for CPI analysis
• Single page for all condition and parameters, very simple
• Rich material data, select material from database directly and database management
• All conditions and parameters could be save as CSF template and use back anytime
• No requirement for CAE knowledge, very short leaning curve
45. CAST-DESIGNERTM
Cast-Designer CPI Flow Chart
CAD Data
Gate System
CPI Meshing
CPI Setup
• Perform simulation and result
analysis
• High-end technology with very fast
simulation speed, tens minutes to
one hour depend the model size
• Batch simulation mode and multi
tasks could be controlled easily
• Using ParaView as post-processors,
very powerful, flexible and without
limitation
• Rich analysis result in various format,
support animation and VRML
• Support plug-in filter for post-process,
similar concept as Photoshop
Post Result
47. CAST-DESIGNERTM
Meshing technology in Cast-Designer CPI
• Innovation technology for meshing generation
• Very simple for operation
• With coarse mesh, mesh layer and advance
geometry mapping (mesh smoothing) technology
• Extremely better for accurate in filling pattern and
pouring time
Full automatic meshing. All
functions has summarized
in one windows page.
Excellent meshing
capability. From
CAD to final
meshing in 5 min.
48. CAST-DESIGNERTM
Meshing technology in Cast-Designer CPI
Thanks the FEM technology, the Cast-
Designer mesh can have a good describe
of the CAD geometry special for the
curved region.
CAD model
Enlarge the
mesh
50. CAST-DESIGNERTM
CAST-DESIGNER vs Traditional CAD & CAE
Traditional
CAD + CAE
Cast-Designer
Preparation the geometry for
simulation
3h 10 mins
Mesh and Setup the model 2h 15 mins
CPU time 10h 1.5h
Design #1 1 Day < 2 hours
Modify geometry 1h 10 mins
Remesh and re-setup 2h 15 mins
Re-run the simulation 10h 1.5h
Design #2 1 Day < 2 hours
Try 4~5 times 5 Days vs 1 Days
55. CAST-DESIGNERTM
Design plan A: Model Size Elements: 20,157 CPU: 605 Sec for filling 702 Sec for all
Design plan B: Model Size Elements: 18,928 CPU: 473 Sec for filling 660 Sec for all
Cast-Designer Solution Comparison
56. CAST-DESIGNERTM
Stress and deformation analysis
• Mechanical Stress Module: Cast-Designer with mechanical stress and
deformation simulation capability. Thanks the FEM base technology, no addition
mesh and couple calculation in Cast-Designer, one mesh for everything.
57. CAST-DESIGNERTM
Stress and deformation analysis
Part deformation after
casting
Cast-Designer provides the detail
information of the part deformation and
distortion after casting. The system
consider both the part and mould of the
solidification process. It is full couple of
the thermal-flow-stress fields.
58. CAST-DESIGNERTM
Stress and deformation analysis
Part deformation result comparison between the actual measurement and simulation
The first line picture was the actual measurement result and the second line was the simulation result.
59. CAST-DESIGNERTM
Components or Modulus of Cast-Designer
Cast-Designer Basic
Cast-Designer CPI
The full Cast-Designer system includes the
following components, which could be a
complete solution or selected alone as a sub-
system.
Cast-Designer Basic
Expect system for gating system,
overflow system and cooling
system design for gravity casting
Cast-Designer CPI
An Upfront analysis system for
metal flow and solidification
analysis to support ‘decision make’
of die casting system bases on the
last CAE technology in an time
economic method
Cast-Designer / CPI
for MCAD
Integrate Cast-Designer / CPI to
MCAD system (Pro/E, UG NX,
Solidworks etc.)
Geo-Designer
DFM tools for casting part checking,
also with on-live functions for riser
and feeder design
60. CAST-DESIGNERTM
2004~ 2010SolidWorks
17 ~ NX 7UG NX
2000 ~ WF5Pro-ENGINEER
SUPPORT VERSIONSCAD SYSTEM
2004~ 2010SolidWorks
17 ~ NX 7UG NX
2000 ~ WF5Pro-ENGINEER
SUPPORT VERSIONSCAD SYSTEM
• Cast-Designer build in
the existed CAD system
• Familiar working
environment, save
learning time
• No data transfer
problems. The system
handle all the data
automatically to avoid
data lose
• Better integration with
design data
management capability
• Full function as
standard software
version and widely CAD
version support
Cast-Designer for MCAD System
for Pro/ENGINEER
Wildfire
for Siemens
UG NX
For DS
SolidWorks
