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A rendering of a cast metal part with stiffeners placed within the chassis of a vehicle.

Altair® Inspire™ Cast

Design, Simulate, and Optimize Metal Casting Processes

From product designers to foundry engineers, Altair Inspire Cast is a complete, robust, and easy-to-use metal casting simulation software for beginners and experts alike. Applied early in the part design cycle, it reduces costly, time-consuming iterations between design and manufacturing. Inspire Cast supports a wide set of casting processes and conditions, helping users make smarter decisions to improve product quality and profitability. Its geometry- and part-centric approach makes it easy to resolve problems early, run analysis, optimize, validate, and cast all within one comprehensive environment.

Inspire Cast uniquely blends casting simulation with practical artificial intelligence (AI), combining data-driven machine learning with physics-based simulation—no deep expertise in finite element methods or AI required. By learning from past simulations, it accelerates design cycles, optimizes performance, and democratizes casting design, giving users a competitive edge.

Why Inspire Cast?

Thickness analysis of a high pressure die cast (HPDC) part pinpoints potential defect zones before production.

Accelerate Casting Development

Inspire Cast is a complete, modern solution for simulating metal casting. Its unique geometry-driven, part-centric workflow helps identify issues early, reduce scrap, lower costs, and bring high-quality cast metal parts to market faster.

Cast metal part inside mold showing cooling and cycle analysis to predicted defects.

Design for Manufacturability

Designing parts without considering cast manufacturability ultimately leads to pattern and tooling rework, delays, and faulty parts. Inspire Cast integrates simulation directly into early stages of product development, helping to identify and solve manufacturing issues upfront and avoid time-consuming back-and-forth iterations between design and manufacturing.

Twin workstation screens in a factory showing design of cast metal part plus AI exploration to compare, refine, and accelerate design decisions.

AI-Powered Casting Simulation

Simulation in Inspire Cast delivers instant insight into mold and die behavior before tooling is made. Combine decades of foundry know-how with modern design and AI tools to explore iterations faster, reduce analysis loops, and optimize outcomes, regardless of part geometry complexity.

Key Features

Simple 5-Step Workflow

Use templates to simulate casting processes, such as high and low pressure die casting, gravity sand, and investment casting. Create runner and gating system geometries to optimize the casting process, all within one comprehensive environment and user-friendly interface.

Design-Centric Features

Perform quick analyses based on geometry to check part manufacturability, including mold opening direction, thickness, filet radius, and porosity review.

Complete Casting Analysis

Analyze every stage of the casting process with Inspire Cast’s low/no code finite element-based analysis, enabling accurate prediction of defects and process optimization across cycling, filling, cooling, solidification, warpage, and trimming.

Validate Full Casting Designs

Simulate and validate complete casting designs, including cavities, runners, and overflows, as well as critical casting components such as shot sleeves, chillers, risers, sleeves, filters, and more, ensuring a comprehensive and optimized casting process. Run structural simulations within the tool using data from casting simulations.

Fast, Accurate Computation

Utilize parallel processing to significantly reduce calculation time on a standard workstation. Inspire Cast supports MPI-based computing in clusters, enabling even faster simulations by leveraging distributed processing across multiple nodes.

AI-ready with Historical Casting Simulation Data

Train machine learning models with historical, geometry-centric Inspire Cast simulations for instant AI insights.

Connect to Structural Solvers

Automatically transfer thermomechanical results, such as residual stresses, from casting simulations to structural solvers. Ensure accurate initialization of stress fields for structural analysis through a fully automated workflow.

Built-in Design of Experiments (DoE)

Define key variables such as geometric parameters or boundary conditions and automatically run multiple simulation scenarios. Explore design options systematically to identify the optimal performance, quality, and robustness of the casting process.

Python APIs

Leverage full control over simulation setup and execution through scripting. Use the API to launch thermal simulations,. automate workflows, integrate seamlessly with external platforms, and drive advanced design optimization.

Inspire Cast Capabilities

Simple 5-Step Workflow

 

Gravity Casting

 

Investment Casting

 

Tilt Pouring

 

High Pressure Die Casting

 

Low Pressure Die Casting

 

AI-powered Casting Simulation