Flow-3D CAST V2025

FLOW-3D CAST is a state-of-the-art metal casting simulation modeling platform that combines extraordinarily accurate modeling with versatility, ease of use, and high performance cloud computing capabilities. For every metal casting process, FLOW-3D CAST has a workspace ready to put you on a quick, intuitive path to modeling success. With 11 process workspaces, powerful post-processing, pioneering filling and solidification and defect analysis, FLOW-3D CAST delivers both the tools and roadmap for designing optimal casting solutions.

The High Pressure Die Casting Workspace is an intuitive modeling environment designed to help engineers successfully model high pressure die casting applications with FLOW-3D CAST. Full control of shot sleeve motion, combined with advanced die thermal control, machine parameter modeling, and accurate resolution of fill and backpressure conditions make FLOW-3D CAST the reference solution for the most demanding HPDC simulation needs. In addition to advanced porosity prediction and post-processing functionalities, the HPDC Workspace includes a state-of-the-art chemistry-based solidification and material strength model for Al-Si and Al-Cu based alloys.

The Tilt Pour Casting Workspace is an intuitive modeling environment designed to help engineers successfully model tilt pour casting applications with FLOW-3D CAST. The workspace includes process-specific die and material types, where rotational motions are easily defined in order to match exact machine capabilities. Venting and backpressure are included in the fill analysis for a complete analysis of air entrapment defects, while thermal die cycling and state-of-the-art solidification models are seamlessly connected to the fill through the workspace’s sub-process architecture. The Tilt Pour Casting Workspace provides a complete and accurate solution for all aspects of the simulation in a simple yet versatile modeling environment.

The Continuous Casting Workspace provides continuous casting users with an easy-to-use tool for simulating all the commonly used foundry processes, including continuous billet casting as well as direct chill continuous casting. With the new Continuous Casting Workspace, users will find the tools they need to model their continuous casting process and optimize process parameters. Multi-block meshing provides an efficient method for even more accuracy in high shear and high temperature gradient regions of the casting. Process parameters such as mold and billet cooling, melt flow rate, superheat, and mold geometry are included in the analysis. Melt surface evolution and mold motion are quickly visualized during post-processing where fill and solidification patterns are also readily assessed, so that process modifications can be implemented with confidence.  

The Low Pressure Sand Casting (LPSC) Workspace provides an easy-to-use tool for simulating all the processes commonly used in the foundry. With the new LPSC Workspace, users have the tools they need to model and optimize their process parameters. Filters can be inserted into the bottom fill sprues to further control the fill patterns and eliminate impurities in the melt. FLOW-3D CAST provides ceramic filters for modeling their impact on the flow during filling. The LPSC Workspace provides exothermic riser assemblies and insulating sleeves to address shrinkage and porosity in the solidifying casting. Using FLOW-3D CAST’s roto-tilt feature, the mold can be flipped upside down prior to solidification so that the filling sprues can act as risers. This approach can eliminate the need for additional risering if the filling sprues are appropriately designed. 

The Low Pressure Die Casting Workspace is an intuitive modeling environment designed for engineers to successfully model low pressure die casting applications with FLOW-3D CAST. Flexible pressure controls allow engineers to accurately reproduce pressure, venting and backpressure conditions in order to deliver a complete analysis of fill, air entrapment and porosity defects. Die thermal management and state-of-the-art solidification models seamlessly connect to the fill through the workspace’s sub-process architecture. The Low Pressure Die Casting Workspace provides a complete and accurate solution for all aspects of the simulation in a simple yet versatile modeling environment.

The Lost Foam Casting Workspace provides lost foam casters with all the tools needed to simulate the filling, solidification and cooling subprocesses. Each subprocess is based on a template design which is tailored to provide a clean, easy-to-use setup interface that speaks the language of the casting process engineer. Since most defects in lost foam castings can be traced back to the filling profile, FLOW-3D CAST’s extraordinary accuracy in simulating metal flow and foam burning provides invaluable insights for producing high quality lost foam castings. Filling defects such as foam residue formation are accurately tracked and located in the final casting.

The Sand Core Making Workspace provides users with an easy-to-use tool for modeling the shooting and hardening of sand cores. Users will be able to model the shooting of a wide range of sand and binder combinations to predict how a core box fills, locate regions where inadequate filling occurs, and then place and size air vents to improve filling in those regions. All current core hardening processes can be modeled including cold box, hot box, and inorganic processes. Shooting characteristics such as sand density distribution and air flow can be readily visualized.  

The Gravity Die Casting Workspace is an intuitive modeling environment designed to help engineers successfully model gravity die casting applications with FLOW-3D CAST. Ladle motion, venting and backpressure are included in the fill analysis for an accurate prediction of air entrapment and porosity defects, while die thermal management and state-of-the-art solidification models seamlessly connect to the fill solution through the workspace’s sub-process architecture. The Gravity Die Casting Workspace provides a complete and accurate solution for all aspects of the simulation in a simple, versatile modeling environment.

The Centrifugal Casting Workspace provides centrifugal casting users with an easy-to-use tool for simulating horizontal and vertical true centrifugal castings, semi-centrifugal castings, and centrifuge castings. With the new Centrifugal Casting Workspace, users will find all the tools needed to model their process and optimize design parameters. Spinning molds and rotating meshes provide users with the flexibility to model any mold motion imaginable including ladle pouring. 

The Sand Casting Workspace provides sand casters with all the tools needed to simulate their filling, solidification, and cooling analyses. The Sand Casting Process Workspace provides the user with a templated design tailored to deliver a clean, easy-to-use setup interface that speaks the language of the casting process engineer. 

The Investment Casting Workspace provides investment casters with an easy-to-use tool for simulating all aspects of investment casting, including shell generation, filling, solidification (with either static or moving Bridgman shell molds), and cooling. A shell mold creation tool is provided for quick and reliable shell geometry creation, while radiation and view factor models accurately capture radiative heat transfer between different parts of the shell. For directional solidification, a moving oven with a hot upper section separated from a cooler lower section captures the Bridgman process. Melt surface evolution as well as mold motion, filling detail and solidification patterns are readily assessed through intuitive post-processing tools, allowing for process modifications to be implemented with confidence.