consultancy Services


Casting Simulation services :


Auto Design Online is a mutual partner from foundries across India, enables foundries to effectively design, evaluate and optimize their casting design with the help of Cast-Designer.

Our service will help you to avoid expensive trial and error processes on real prototypes during the product and mould development cycle, which will save expensive material, labor cost and manpower.

We provide the simulation service for various casting process e.g. HPDC, LPDC, Gravity casting, Investment casting, Tilt casting etc. Interested foundries can avail any of below services as per their requirement and need.

1 : Evaluate casting design developed by foundry

Engineering Service can be used to solve various problems in existing or new castings in those foundries who does not own any casting simulation software. Simulation Service is an inexpensive way to locate problem areas and identify reasons for problems. Different casting solutions for the problem can be simulated quickly.

In foundry designer may have various possible concept/ideas for gating system design of any casting part & process. These ideas can be verified through Cast-Designer casting simulation. Software helps to find out which is the best design among 4-5 concept, and then the best design needs to be produced in foundry. Using Cast-Designer one can easily evaluate 4-5 concepts within a week. So in week time foundry can finalize their casting design of even any new product and start production of casting defect free part. Necessary tests (X-Ray, Radiography, destructive-non destructive test) can be carried out on prototype to verify the accuracy of Cast-Designer.



To avail this service foundry needs to have 2D sketch or 3D model of casting part & gating system design/concept. Our engineer will evaluate this concept/design and provide full report with the details of each design its feasibility, casting defect, animations etc.

Required Input :

  • Casting part (2D sketch or 3D Geometry)
  • Details of gating system design (2D sketch or 3D Geometry of Gate, Runner, Sprue, Riser, Hot/Cold Chamber)
  • Casting process details (Pouring temperature, Casting material details etc.)

Simulation Service Result (Output) :

Standard output is the Microsoft powerpoint format report with eventual problems description with animations.

  • Mold filling animations, detect if any filing problem!
  • Gas/Air Entrapment animation, identify location if gas/air could not escape!
  • Solidification animation, identify liquid spots!
  • Solidification times and directions
  • Shrinkage/Porosity detection
  • Hot spots

2 : Casting design, development & optimizationof new casting/product development

If casting foundry is interested to outsource their casting design and development, our foundry expert and experience design engineer could provide complete consultancy. We can design gating design, evaluate and optimize using Cast-Designer. And foundry will get 3D model of complete gating system design and report of simulation as an output. WE are the one step solution for any new product development of your foundry.

Foundry can start production of any new casting part within a week time working closely with an expert engineer of Auto Design Online.



Required Input :

  • Casting part (2D sketch or 3D Geometry)
  • Casting process details (Pouring temperature, Casting material details etc.)

Simulation Service Result (Output) :

Standard output is the Microsoft powerpoint format report with eventual problems description with animations.

  • 3D model in .STEP or .IGES format of full gating system design
  • Mold filling animations, detect if any filing problem!
  • Gas/Air Entrapment animation, identify location if gas/air could not escape!
  • Solidification animation, identify liquid spots!
  • Solidification times and directions
  • Shrinkage/Porosity detection
  • Hot spots

If you are interested for casting simulation service, we would be very happy towork with you as one team and provide you required assistance for existing casting part or new development. Feel free to contact us (url link jump to contact us page) for any of your requirement.

Foundry Consultancy :


The term “consulting” is usually understood to mean a structured discussion or a corresponding form of communication or even practical guide with the aim of solving a problem or approaching a solution.

First of all we are not management consultants. We are involved in what is really a very small market but one which is of global significance – the foundry industry. Even if metal has been being melted for thousands of years, the processes in foundries are just as subject to change as those in other industries. In order to understand these changes you need specialist knowledge. Knowledge which we have acquired and really taken on board over the last 30 years, knowledge which has seen and fundamentally changed more than 100 foundries. We do not only use this knowledge to change or introduce our products but also to carry out completely neutral feasibility studies and give process and organizational advice by means of our consulting services in foundries.

Our consulting focus is :

  • Flexible calculation of planned costs, process-costs, construction of patterns and apparatus
  • Pre- and post-calculation of castings, patterns and apparatus
  • Modelling of processes:
  • Modelling of processes:
    o Production-, capacity- and investment-planning
    o Inquiry for new parts: planning, calculation, offer creation as well as management from orders to delivery of the initial sample
    o Order management and logistics for single-part or batch-production, make-to-order, make-to-stock, consignment stock, EDI and kanban
    o Production planning and control, supply chain management, control of external service providers, shop-floor data capture, material management
    o Material flow, traceability of melting charges, serial numbers, display of raw material stock, work in progress and finished goods, traceability of undefined quantities as well as handling units
    o Combined production
    o In compliance with DIN EN ISO 9001 / 9004 and International Railway Industry Standard (IRIS)
  • Foundry Information System (FIS)
  • Foundry Information System (FIS)
    o Internal benchmarking
    o Knowledge-based engineering (KBE) and electronic content management (ECM) in production
    o Product Data Management, Lifecycle-Management
  • OPTI.melt - Comprehensive management of values and quantities in the melt shop, incl. batch optimization and melting report.

If your foundryis interested in our consulting services, please contact us (url jump to contact us page), we would be very happy to serve you and work as a team.

We are looking forward to getting to know you!