CastingSimulation.in, operated by ProSIM, is a leading consultancy specializing in advanced casting simulation services using the globally renowned ADSTEFAN software. Developed by Hitachi and based on the pioneering research of Professor Niyama from Tohoku University, ADSTEFAN is at the forefront of modern casting technology, offering unparalleled precision and insight into complex foundry processes.

What They Do

CastingSimulation.in provides comprehensive casting simulation solutions to foundries across the globe, including hundreds of clients in India and abroad. Their primary focus is on helping manufacturers optimize casting processes, reduce defects, and enhance product quality — all through virtual simulations that eliminate guesswork and costly trial-and-error approaches.

Key Services

1. Comprehensive Process Coverage

CastingSimulation.in supports simulations across a wide range of casting processes, including:

Sand casting and shell molding

Investment casting

Gravity die casting (GDC)

High-pressure die casting (HPDC)

Low-pressure die casting (LPDC)

Centrifugal casting

Squeeze casting

Rheo/thixo casting

Tilt-pour and direct-chill casting

This broad coverage ensures that foundries across various industries can leverage simulation to improve performance and output.

2. Defect Prediction and Optimization

Using the robust capabilities of ADSTEFAN, the platform accurately simulates:

Flow and Filling: Predicts issues such as turbulence, cold shuts, and die erosion.

Solidification: Helps identify shrinkage porosity, hot tears, and misruns.

Air Entrapment: Maps regions vulnerable to gas porosity and blow holes.

Crack Formation: Forecasts thermally induced cracks using thermal stress and gating design analysis.

By simulating these critical factors, engineers can proactively address potential quality issues before production begins.

3. Virtual “What‑if” Optimization

CastingSimulation.in enables engineers to virtually test different design iterations and process parameters, including:

Gating and riser design

Venting and cooling system configurations

Pouring temperature and speed

This digital experimentation drastically reduces the time and cost associated with physical trials while enabling higher degrees of accuracy and process efficiency.

4. Tangible Outcomes

Through precise simulation and optimization, CastingSimulation.in has delivered measurable improvements for clients. Outcomes include:

Reduced rejection rates

Increased material yield

Lower energy consumption

Faster casting defect analysis product development cycles

In one notable case, a gravity die casting operation saw yield improvement from 22% to 76% following the implementation of simulation-driven changes.

Why It Matters

India is the second-largest producer of castings globally, with over 14.16 million metric tonnes produced in 2022–2023. The casting industry is under continuous pressure to meet quality standards while managing cost and lead times. Simulation technologies, such as those offered by CastingSimulation.in, are essential in overcoming these challenges. They help manufacturers stay competitive, meet international standards, and adopt sustainable practices.

Conclusion

CastingSimulation.in stands at the intersection of metallurgy, simulation, and innovation. By Casting crack prediction offering ADSTEFAN-based simulation solutions across all major casting techniques, the consultancy empowers foundries to enhance quality, reduce waste, and optimize production. As the demand for precision casting continues to rise, solutions like those from CastingSimulation.in are not just advantageous — they are indispensable for modern manufacturing.