Table of Contents
ProCast 2025
ESI ProCast is a comprehensive 3D simulation solution for metal casting processes, developed by ESI Group – a pioneering corporation in the field of virtual prototyping and physical prototype simulation. The software utilizes the advanced Finite Element Method (FEM), allowing for accurate prediction of physical phenomena occurring during mold filling, solidification, and cooling.
Unlike conventional simulation tools, this solution not only evaluates material flow but also delves into the microstructure analysis, residual stress, and deformation of the casting. This forms the core basis for mold technology engineers to make scientifically sound decisions regarding the gating and riser system before proceeding with actual mold manufacturing. See more GstarBim
Features of ProCast
- Flow Analysis
- The software visualizes how molten metal fills the mold cavity. Engineers can easily detect turbulent flow areas, air leaks, poor flow integration (cold joints), or areas where the metal cools prematurely before complete filling.
- Thermal & Solidification Simulation
- The phase transition from liquid to solid directly determines the compactness of the casting. This tool accurately calculates the temperature distribution over time, thereby predicting locations prone to shrinkage cavities, porosity, or concentrated shrinkage pockets, helping engineers calculate the optimal size and placement of shrinkage pockets.
- Stress & Distortion Analysis
- One of the software’s proprietary features is its stress analysis module. The software can predict hot tearing trends during solidification, cold tearing during cooling, and accurately measure the geometric deformation of castings after demolding.
- Rich material library and microstructure calculations
- The software integrates a huge material database including cast iron, steel, aluminum alloys, magnesium, titanium, etc. In particular, the system can predict the mechanical properties of the cast product such as hardness and tensile strength by simulating the phase formation process and fine/coarse grain structure.
- ESI ProCast is a versatile solution capable of simulating most common casting methods currently used in industry:
- Sand casting: Predicts heat transfer between metal and sand, calculates mold gas permeability.
- Pressure casting (High Pressure Casting – HPDC, Low Pressure Casting – LPDC): Accurately simulates high injection velocity, holding pressure, and thermal cycle of metal molds to optimize mold cooling systems.
- Investment casting (Precision Casting): Simulates ceramic coating, mold firing, and complex thermal radiation effects between castings in the pattern beam.
- Centrifugal and continuous casting: Calculates the influence of centrifugal force and workpiece pulling speed on surface quality and internal structure.
System requirements of ProCast
- Operating System: Windows 7/8/10/11
- Free hard disk space: 2 GB of hard disk free space minimum
- Installed memory: 4 GB minimum RAM
- Processor: Intel multi-core processor or higher
ProCast Free Download
ESI.ProCAST.Suite.2025.0
ESI_ProCAST_2021.5
How to install ProCast
- Turn off anti-virus software (Note also turn off Windows Defender)
- Extract the downloaded software
- Run Setup to install the software
- See readme.txt
- Done
