OPTIMIZATION OF CASTING PROCESS DESIGN USING SOLIDCast® and HyperOpt®


OPTICast® is a new software product that works in conjunction with the SOLIDCast® solidification modeling system. OPTICast® uses theHyperOpt® system from Altair Engineering, Inc., the leader in the field of optimization software.

What does Optimization do?

Most solidification modeling systems require the engineer to create a design, run a simulation, review the results, and then make a decision about how to modify the design to achieve a good casting. This can take several design iterations to get to the end result.

Optimization is a technique that allows the foundry engineer to start with an initial design for a casting, with gating and risering, as a 3D model in the SOLIDCast® modeling system. The user then selects the following elements:

Design Variables: These are elements of the design that are allowed to vary. For example, this could be the height and diameter of a riser. It could also be the pouring temperature of the alloy, or the preheat temperature of an investment shell.

Constraints: These are specifications for results that determine whether a particular design is acceptable. For example, the foundry engineer might specify a certain yield percentage as the minimum value acceptable. One might also specify a certain level of macroporosity as the maximum level acceptable.

The Objective Function: This describes what the foundry engineer is trying to achieve. Examples might be to maximize the yield, minimize shrinkage or minimize the total solidification time.

Once these elements are identified in the model, the user then launches an Optimization Run. This consists of a series of simulations in which the design conditions are varied under the control of HyperOpt®, model changes are made and simulation results are evaluated, all completely automatically, until the desired result is achieved. 

Using OPTICast®, the foundry engineer can start with an initial design and allow the computer to do the work of modifying the design and running simulations to achieve an optimum result.


Now, for the first time, the technology of automated design is brought to the foundry in the form of a practical and easy-to-use design tool.OPTICast® can help you to improve your yield and your quality to an optimum point, while freeing design engineers from the repetitive task of trial-and-error design.


Steel Casting with Optimized Riser Design 
13% Yield Improvement, automatically!


Contact us for more details about this exciting new technology.