Description

CAST-DESIGNER 7.10 by C3P Software

Advanced End-to-End Casting Simulation, Tooling Design, and Manufacturing Optimization Platform

CAST-DESIGNER 7.10 represents the most advanced and fully integrated release of C3P Software’s digital casting engineering platform. Designed for die casting, gravity casting, investment casting, low-pressure casting, sand casting, and thixo-moulding, version 7.10 provides a complete CAD–CAE–CAM workflow that connects product design, gating system design, cooling layout, ejection layout, simulation, optimization, and production validation in one unified software environment.

With dramatically improved automation, a new high-performance mesh engine, enhanced surface-handling algorithms, and new modules for conformal cooling and magnesium thixo-moulding, CAST-DESIGNER 7.10 delivers major improvements in speed, accuracy, productivity, and design reliability across the entire casting lifecycle. It is engineered to support modern foundries, OEMs, tooling manufacturers, and engineering service providers seeking to reduce costs, eliminate defects, accelerate development, and transition to data-driven digital manufacturing.

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Major Improvements and New Functions in CAST-DESIGNER 7.10

1. Smart Cooling – Advanced Automated Cooling-Channel Design

A cornerstone of the 7.10 release is Smart Cooling, a next-generation automated cooling-channel design tool purpose-built for die-casting toolmakers and casting engineers.

Key capabilities:

• Automated cooling-channel layout generation based on alloy selection, cycle time, thermal budget, heat-load classification, and target cooling zones

• Supports conformal cooling, spiral channels, zigzag channels, and advanced insert cooling

• Allows engineers to define boundary targets and automatically compute optimal channel positions

• Integrated cooling-performance evaluation: thermal distribution, hot-spot relief, and cycle-time impact

• Export to STEP, CSV, and Excel with macros for CAD/CAM toolchain integration

• Up to 10–30× faster than traditional manual cooling design practices

• Ideal for HPDC dies, multi-cavity dies, and components with complex wall thickness

This module directly reduces die-surface overheating, shortens cycle time, improves dimensional accuracy, and significantly extends die life.

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2. Smart Ejection – Automated Ejector Pin Planning and Validation

CAST-DESIGNER 7.10 introduces Smart Ejection, a powerful automated ejector-pin placement and evaluation system.

Features include:

• Automated ejector-pin placement based on product geometry, pulling direction, friction zones, and area stiffness

• Identification of critical ejection regions that require reinforcement

• Simulation of ejection-force distribution to detect pin over-loading, insufficient support, or potential casting damage

• Configurable rules for pin diameter, spacing, and tolerance

• Manual fine-tuning tools for expert adjustment

• Automatic reporting for tooling documentation

This technology reduces reliance on senior tooling designers, improves design repeatability, and prevents costly tool corrections after manufacturing.

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3. High-Capacity Mesh Engine – Handle Ultra-Large Models Seamlessly

The new FastMesh engine in version 7.10 offers extreme performance and reliability for high-fidelity casting simulation.

Enhancements include:

• Support for 200+ million element CAE meshes, depending on workstation memory

• Faster, parallelized meshing using multi-core CPU acceleration

• Flexible 3D Mesh capability:

  • Automatically handles imperfect STL geometry

  • Automatically repairs small gaps, overlaps, noisy surfaces

• Mesh-based Boolean operations

• Local mesh refinement to improve accuracy in gating, runners, thin-wall areas, and hot spots

• High-performance mesh compression for large job storage

These improvements enable giga-casting, large structural parts, heavy-industry components, and complex thin-wall automotive castings to be simulated with unprecedented fidelity.

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4. Magnesium Thixo-Moulding Module

CAST-DESIGNER 7.10 expands support for advanced materials with a new Mg thixo-moulding module, featuring:

• Temperature-dependent thixotropic flow modeling

• Semi-solid metal (SSM) flow behavior simulation

• Material and process wizards for magnesium alloys

• Machine settings optimization

• Validation against industrial thixo-moulding production lines

This makes CAST-DESIGNER one of the very few software platforms capable of end-to-end engineering simulation for magnesium thixo-moulding — critical for ultra-lightweight automotive, electronics, and aerospace components.

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5. Enhanced Gating System Design

The improved gating and runner system in version 7.10 offers:

• Automated gating layout recommendations

• Improved visualization for flow balancing

• Enhanced functionality for HPDC, gravity casting, sand casting, and investment casting

• Better integration between CAD design, CAE simulation, and tooling workflow

• Ability to test multiple designs in parallel with fast mesh generation

Gating design becomes more predictable, easier to optimize, and integrated tightly with the overall casting process.

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6. Full Simulation Workflow Enhancements

CAST-DESIGNER 7.10’s improved simulation algorithms deliver high accuracy for:

• Metal flow

• Solidification

• Micro-porosity prediction

• Air entrapment

• Shrinkage defects

• Cold shuts

• Surface quality

• Residual stress

• Casting distortion / warpage

• Hot tearing risk

Improved thermal-structural coupling and more stable solvers ensure simulation reliability even in large-scale industrial projects.

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Bug Fixes and Stability Improvements

Version 7.10 integrates a long list of stability and robustness improvements, including:

• Stronger STL handling for poor-quality reverse-engineered models

• Higher success rate in automatic CAD import and geometry healing

• Reduced meshing failures caused by thin features or micro gaps

• Faster convergence in coupled thermal-mechanical analysis

• More consistent results in multi-run optimization workflows

• Improved handling of extremely complex gating systems

• Enhanced memory management for massive mesh models

• Significant reduction in solver crashes due to boundary setting conflicts

These improvements collectively make the 7.10 release one of the most stable and production-ready versions to date.

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System Requirements (Recommended)

While exact specifications depend on project scale, typical recommended hardware includes:

Minimum Requirements

• Multi-core CPU

• 16 GB RAM

• Standard professional GPU

• SSD storage

• Windows-compatible workstation environment

Recommended for Large Simulations

• High-end multi-core CPU (12–32+ cores)

• 64–256+ GB RAM (required for 50M–200M+ element meshes)

• High-performance NVMe SSD

• Large storage capacity for simulation files

• Dual-monitor or wide-screen display for engineering workflow

CAST-DESIGNER is primarily CPU-based, so memory capacity and CPU speed have the greatest impact on performance.

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Interesting Facts and Competitive Advantages

• CAST-DESIGNER is one of the few casting solutions combining CAD + simulation + tooling automation in one platform.

• Many global OEMs in automotive, aerospace, and consumer electronics use CAST-DESIGNER for ultra-lightweight structural parts.

• The Smart Cooling and Smart Ejection modules significantly reduce dependency on senior tooling designers.

• CAST-DESIGNER is known for its speed; in many benchmarks it runs significantly faster than traditional casting simulation tools.

• The software is frequently used for research in die-life prediction, process optimization, and alloy development.

• Its support for magnesium thixo-moulding sets it apart from most conventional casting CAE systems.

• Flexible license modules allow organizations to scale capabilities as projects grow.

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Why CAST-DESIGNER 7.10 Is a High-Value Investment

CAST-DESIGNER 7.10 is designed for manufacturers who need:

• Faster design cycles

• Fewer casting defects

• Reduced scrap and rework

• Lower tooling costs

• Accurate digital prediction before production

• Advanced process automation

• Ability to handle modern casting challenges, including complex alloys and giga-castings

Whether you operate a foundry, serve as an OEM, or manufacture tooling, CAST-DESIGNER 7.10 provides the technological depth, automation, and workflow integration required to remain competitive in today’s casting industry.

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★★★★★ – Powerful and Reliable Casting Simulation Software

As a developer working daily with casting and tooling simulation, CAST-DESIGNER 7.10 is one of the most efficient and accurate platforms I have used. The new Smart Cooling and Smart Ejection features dramatically reduce manual design time, while the upgraded FastMesh engine handles large and imperfect models with impressive speed and stability. Simulation results for flow, solidification, and porosity prediction are consistently reliable, which makes design validation faster and far more confident. For any engineering team focused on high-quality casting, reduced defects, and optimized tooling, CAST-DESIGNER 7.10 is a top-tier choice.