Mold Flow Simulation Modeling

Mold Flow Simulation: The Secret to Perfect Die Casting 

Mold flow simulation is an excellent tool that allows Deco engineers to understand zinc alloy flow in a die cast mold before the actual casting process takes place. This process can help Deco engineers anticipate potential issues that may arise during the die casting process and resolve them during the tooling design stage and before the mold is fabricated.  

Using software called Flow3D-Cast, Deco engineers can now simulate the entire die casting process.  This cutting-edge technology provides unprecedented insight into what happens inside the mold during the die casting process. 

Unveiling the Power of Mold Flow Simulation 

The processes that take place inside the die casting mold remain a perplexing challenge with many variables being impacted by the part and tool geometry.   During the die casting process, molten metal is rapidly injected into the mold cavity, splashing on walls and cores and cooling at different rates.  

Additionally, air in the cavity moves and can impact part function if not considered.  Some of the air is designed to be displaced into vents and overflows to ensure high material integrity in key areas of the part.  The physics behind a shot is incredibly complex and calculating it would be very difficult and thus the simulation software can be an essential tool for this optimization.   

How Deco Engineers Use Flow3D-Cast to Improve Die Cast Quality 

With Flow3D-Cast, Deco engineers can slow the process down and examine the metal flow patterns, pressures, temperatures, and velocity. They can also watch air and metal interact at the wave front. 

With the help of mold flow simulation technology. Deco can predict surface defects, blistering, and porosity that may occur during the casting process. This insight enables Deco to proactively design out these issues before the die casting process begins, ensuring optimal die cast quality. 

Often during these essential tool design activities, multiple iterations of mold flow will be needed.  These iterations allow for trials to further optimize the tool design—all rapidly performed and before the expensive tooling fabrication process.  So, when tool steel is “cut” a higher confidence and lower cost tooling implementation can result. 

See below video for example of a simulation.  


Mold flow simulations are often performed on new designs, but also tool design optimization actually could be performed existing molds to predict further improvements for fill or cost efficiencies.

Additionally, mold flow simulation can simulate gating options, overflows, and vents for new projects. The entire shot can be optimized before the mold is produced. Regardless, Deco Products has the expertise and the tools to help make our customer projects successful. Visit our tool design page for additional information.

Since 1960

Deco Products has been a “Made in USA” zinc die casting manufacturer since 1960. Deco Products provides exceptional service and quality products for a multitude of industries. A few services Deco Products provides are custom precision engineered zinc die casting, powder coating, assembly, CNC Machining, and DFM-Part Design. Learn more about The Deco Advantage.
Picture of Dave Magner

Dave Magner

Dave Magner is the Director of Sales and Marketing and has been with Deco Products since 2015. He has a +20 years of engineering experience in mechanical and electrical testing and design and zinc die casting, plastic injection molding, stamping, assembly, and automation processes.

Quick Links

Sign Up To Deco's Quarterly Newsletter

No spam! Just relevant news, events, and updates about Zinc, Deco, and our services. Sign up for our quarterly newsletter today!

Sign Up To Deco's Quarterly Newsletter

Deco Products is committed to protecting your privacy.  By clicking below, you agree that we may process your information in accordance to the terms defined in our full Privacy Policy statement.