In modern foundry engineering, “design by analysis” has replaced “design by experience” as the foundation of high-integrity casting manufacture. Gone are the days when gating and riser layouts were drawn from rule-of-thumb. Today, every successful casting begins with data — simulation, metallurgical modeling, and a deep understanding of how molten metal behaves as it fills and solidifies.
At Metal Casting Development LLC, we use design-by-analysis principles to develop casting methods that are predictable, repeatable, and efficient. By combining CFD flow modeling, thermal-solidification analysis, and real-world process data, we can visualize the metal path before a single mold is made — identifying turbulence, air entrapment, and shrinkage risks in advance.
But one truth remains consistent across all the data: bottom pouring is the only way to make good castings.
When metal is introduced from below the cavity, it fills smoothly and evenly, without splashing or cascading through air. This laminar flow minimizes oxide generation, prevents cold shuts, and preserves the metal’s cleanliness. In contrast, top or side gating allows free-falling metal streams to fold, trap air, and create oxide bifilms — invisible defects that compromise strength, fatigue life, and leak integrity.
Bottom pouring also supports directional solidification, allowing heat to move upward and feeding to occur naturally. The result is a cleaner microstructure, reduced porosity, and fewer machining issues — especially in thin-wall, high-performance aluminum castings.
The foundries that consistently achieve <1% scrap rates all share this principle: controlled, bottom-fed metal flow designed through analysis, not guesswork.
At Metal Casting Development LLC, every casting method we design starts with that philosophy. Whether it’s a compacted graphite iron cylinder block or a precision aluminum head, our goal is the same — to make sure the first casting poured is already the right one.
Contact us to learn how design-by-analysis and bottom-fill methodology can transform your foundry’s performance.