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<div class="section abstract"><div class="htmlview paragraph">Casting is unique manufacturing processes for variety of reasons. Perhaps the most important reason is, it can produce complex components in any metal and weight ranging from grams to several tons. It is age old technology used to produce complex shapes and for mass production. The defects produced specifically inside the component, during casting process are difficult to identify. These defects in turn become cause of component failure in operating condition. FEA tools gives better understanding of process and can predict any defect produced in the casting process. It also helps to optimize entire process. Thus, use of software are becoming necessity in the industry to avoid rejections / last minute surprise.</div><div class="htmlview paragraph">This paper describes use of simulation to predict casting defects accurately in existing casting component. This provides in depth understanding of existing casting process. With understanding of existing process defects, suitable modifications in the casting design and process were carried out to eliminate persisting casting defect. Production trials were conducted with suggested modifications in the pattern and the process. With suggested modifications, casting defect were eliminated. The modified design also reduced the casting input material weight by ~3% thus improves casting yield.</div></div>