Casting Simulation for In-House Mold Development

Manufacturing · Case Study

Casting Simulation for
In-House Mold Development

Client

KITZ (Thailand) Co., Ltd.

Solution

JSCAST / Casting Simulation

Year

2019

Region

Bangplee, Samut Prakan

Overview

Client Background

KITZ Corporation’s Thai plant produces bronze and brass valves. It established a technical department and began in-house mold production.

The challenge: Molds were outsourced, local know-how was limited, and defect causes were identified through trials and experience.

The QUALICA solution: JSCAST 3D simulation with four services — Casting Process Simulation, Casting Defect Analysis, Mold Development, and Thai/Japanese Technical Support.

The Challenge

Casting mold production had previously been outsourced, making it difficult to develop molds internally.
Kitz needed to build local expertise in casting mold development and simulation.
The flow of molten metal and solidification inside the mold could not be directly observed.
Identifying the causes of casting defects relied heavily on production results and technical experience.

Our approach

The Qualica Solution

Qualica introduced JSCAST, a three-dimensional casting simulation system that enables engineers to visualize metal flow and solidification inside casting molds. The solution supports casting defect analysis and helps Kitz improve its casting mold development process through simulation.

Casting Process Simulation

Visualize metal flow and solidification inside casting molds to better understand the casting process before production.

Casting Defect Analysis

Use simulation results to identify potential casting defects and analyze their causes.

Mold Development

Use simulation to evaluate casting mold designs, runner shapes, and casting conditions during mold development.

Technical Support

Provide technical support in Thai and Japanese to help Kitz understand and effectively use the simulation system.

Results

Predicts mold defect patterns before production
Visualizes metal flow and solidification.
Engineers test ideas without costly trial pours.
Used to adjust runners, add cavities, and modify molds to improve first-pass yield.
Thai staff now discuss technical issues directly, without the director

Client voice

“Being able to have Thai staff talk through technical issues among themselves, without going through me, has taken a lot of weight off my shoulders.”

Noboru Hotta

Director, KITZ (Thailand)

“Easy to understand, convenient to use, and fully featured.”

Noboru Hotta

on JSCAST

Facts & next steps

Plant opened in 1988 · ~1 million valves per month
Technical department founded in 2017 · project started May 2019
Next: rubber valve parts, aluminium die casting, and knowledge-sharing with plants in Japan
Company goal: “Global Strong No.2” in valves by 2030

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Solutions used

JSCAST
Casting Simulation
Defect Analysis
Technical Support

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