Casting Mold Design Course

Lesson 1 • Introduction to Metal Casting Processes

Covers the major casting families and their industrial applications. Establishes context for why mold design decisions differ across process types.

Lesson 2 • Material Considerations for Mold Design

Introduces how cast alloy properties influence mold geometry and material selection. Students connect alloy behavior to specific design constraints.

Lesson 3 • Roles and Functions of a Casting Mold

Explains what a mold must accomplish during filling, solidification, and ejection. Links mold function to downstream part quality outcomes.

Lesson 4 • Quality Standards in Casting Production

Surveys industry quality expectations and defect classification systems. Frames mold design as the primary lever for achieving dimensional and surface quality.

Lesson 1 • Draft Angle Design and Application

Covers draft angle calculation for various alloys and surface finishes. Proper draft prevents part sticking and mold damage during ejection.

Lesson 2 • Parting Line Selection and Strategy

Teaches systematic methods for choosing optimal parting lines on complex parts. Correct parting line placement minimizes flash, undercuts, and tooling cost.

Lesson 3 • Wall Thickness and Rib Design

Addresses uniform wall thickness rules and rib geometry to prevent shrinkage defects. Students apply design-for-casting guidelines to real part geometries.

Lesson 4 • Undercut Management and Side Actions

Explains how undercuts are identified and resolved through side cores and lifters. Students evaluate trade-offs between part complexity and tooling cost.

Lesson 1 • Gating Layout and Cavity Balancing

Addresses multi-cavity mold gating to achieve simultaneous, balanced filling. Balanced layouts reduce scrap from underfill and cold-shut defects.

Lesson 2 • Gate Type Selection by Process

Compares edge, bottom, top, and step gates across casting processes. Students match gate type to part geometry, alloy, and quality requirements.

Lesson 3 • Gate Sizing and Ratio Calculations

Teaches quantitative methods for sizing sprues, runners, and ingates. Correct ratios balance fill time, velocity, and cleanliness requirements.

Lesson 4 • Gating System Components and Functions

Identifies each gating component and its role in controlling metal flow. Understanding component functions is prerequisite to sizing and layout decisions.

Lesson 1 • Feeding Aids and Directional Solidification

Introduces chills, insulating sleeves, and exothermic compounds as feeding aids. These tools extend feeding range and promote directional solidification.

Lesson 2 • Riser Types and Placement Strategies

Surveys open, blind, side, and top risers and their appropriate applications. Correct placement ensures the riser solidifies last and feeds effectively.

Lesson 3 • Riser Sizing Methods

Applies geometric and modulus-based methods to calculate minimum riser dimensions. Properly sized risers eliminate porosity without excessive metal waste.

Lesson 4 • Riser Removal and Yield Optimization

Covers riser neck geometry for easy removal and strategies to maximize casting yield. Yield optimization reduces material cost without compromising soundness.

Lesson 1 • Vent Design for Sand and Permanent Molds

Compares vent geometry and placement strategies across sand and permanent mold processes. Process-specific vent design prevents gas-related defects without weakening the mold.

Lesson 2 • Cooling Channel Design and Layout

Teaches systematic layout of cooling channels for uniform heat extraction. Balanced cooling reduces warpage, cycle time, and thermal fatigue in the mold.

Lesson 3 • Thermal Analysis and Cycle Time Optimization

Uses thermal simulation outputs to identify hot spots and optimize cooling layouts. Students iterate cooling designs to achieve target cycle times and part quality.

Lesson 4 • Gas Generation and Venting Requirements

Identifies sources of gas in molds and quantifies venting needs by process. Adequate venting prevents misruns, porosity, and back-pressure defects.

Lesson 1 • Mold Base Design and Standard Components

Covers mold base configurations, leader pins, bushings, and support pillars. Standard components reduce lead time and ensure interchangeability across mold sets.

Lesson 2 • Mold Steel Selection and Heat Treatment

Compares tool steel grades by hardness, toughness, and thermal fatigue resistance. Correct steel selection extends mold life and reduces unplanned maintenance.

Lesson 3 • Surface Treatments and Coatings

Surveys nitriding, PVD coatings, and mold release treatments for extended service life. Surface treatments reduce erosion, soldering, and sticking in high-volume production.

Lesson 4 • Cavity and Core Insert Design

Addresses insert geometry, retention methods, and interchangeability for cavity and core blocks. Modular inserts enable fast changeover and localized repair.

Lesson 1 • Filling Simulation and Flow Analysis

Runs and interprets filling simulations to detect cold shuts, misruns, and air entrapment. Students modify gating designs based on simulation-identified flow defects.

Lesson 2 • Introduction to Casting Simulation Software

Orients students to simulation software interfaces, input requirements, and output types. Simulation literacy reduces costly physical trials and accelerates design iteration.

Lesson 3 • Solidification Simulation and Porosity Prediction

Analyzes solidification sequence to locate shrinkage porosity and hot spots. Simulation-guided riser and chill placement eliminates defects before tooling is built.

Lesson 4 • Design Iteration and Simulation Reporting

Establishes a structured workflow for simulation-driven design improvement and documentation. Formal reporting communicates simulation findings to tooling and production teams.

Lesson 1 • Precision and Near-Net-Shape Mold Design

Focuses on achieving tight tolerances and minimal post-machining through precision mold design. Near-net-shape strategies reduce machining cost and material waste.

Lesson 2 • Multi-Cavity and Family Mold Design

Addresses layout, balancing, and gating strategies for multi-cavity and family molds. Efficient multi-cavity designs maximize machine utilization and reduce per-part cost.

Lesson 3 • Mold Life Extension and Maintenance Design

Integrates maintenance accessibility and repairability into the mold design from the outset. Designing for maintenance reduces downtime and extends productive mold life.

Lesson 4 • Thin-Wall and Complex Geometry Casting

Covers design strategies for thin-wall, high-aspect-ratio, and topologically complex parts. Students adapt gating, venting, and cooling to extreme geometry requirements.