List of ESI ProCAST Customers
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Since 2010, our global team of researchers has been studying ESI ProCAST customers around the world, aggregating massive amounts of data points that form the basis of our forecast assumptions and perhaps the rise and fall of certain vendors and their products on a quarterly basis.
Each quarter our research team identifies companies that have purchased ESI ProCAST for 2D/3D Simulation from public (Press Releases, Customer References, Testimonials, Case Studies and Success Stories) and proprietary sources, including the customer size, industry, location, implementation status, partner involvement, LOB Key Stakeholders and related IT decision-makers contact details.
Companies using ESI ProCAST for 2D/3D Simulation include: Rolls-Royce Holdings, a United Kingdom based Aerospace and Defense organisation with 42400 employees and revenues of $25.91 billion, MTU Aero Engines, a Germany based Manufacturing organisation with 12170 employees and revenues of $5.36 billion, Wall Colmonoy United Kingdom, a United Kingdom based Manufacturing organisation with 195 employees and revenues of $50.0 million and many others.
Contact us if you need a completed and verified list of companies using ESI ProCAST, including the breakdown by industry (21 Verticals), Geography (Region, Country, State, City), Company Size (Revenue, Employees, Asset) and related IT Decision Makers, Key Stakeholders, business and technology executives responsible for the software purchases.
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| Logo | Customer | Industry | Empl. | Revenue | Country | Vendor | Application | Category | When | SI | Insight |
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MTU Aero Engines | Manufacturing | 12170 | $5.4B | Germany | ESI Group | ESI ProCAST | 2D/3D Simulation | 2022 | n/a |
In 2022, MTU Aero Engines used ESI ProCAST in a joint study to automate detection and prediction of critical porosity and defect sizes in nickel based superalloy investment castings for turbine components. The engagement positioned ESI ProCAST as a 2D/3D Simulation tool supporting quality assurance and materials engineering for cast turbine hardware.
The implementation combined ProCAST simulation outputs with automated image analysis to create a repeatable workflow for porosity identification and sizing. ESI ProCAST simulation runs produced porosity-prone region maps and feeding predictions, which were correlated against microscopy and X ray derived imagery to automate detection and prediction of critical defect sizes. The configuration emphasized simulation driven defect analysis and automated post processing rather than manual trial and error.
The Germany based study covered investment casting feedstock and finished turbine component inspection workflows, aligning manufacturing engineering, materials science, and quality teams around a common simulation to image analysis pipeline. Integrations explicitly included automated image analysis systems linked to ESI ProCAST results to validate simulated porosity against measured defects and to flag areas requiring design or process change. The work focused on component level casting quality for turbine parts rather than upstream enterprise systems.
Governance for the joint study centered on iterative simulation validation and image based feedback loops to inform process adjustments, with study scope limited to research and process improvement activities. Outcomes reported included improved part quality and sustainability through reduced expensive hardware trials and lower scrap generation, driven by earlier detection and prediction of critical porosity in the casting process.
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Rolls-Royce Holdings | Aerospace and Defense | 42400 | $25.9B | United Kingdom | ESI Group | ESI ProCAST | 2D/3D Simulation | 2021 | n/a |
In 2021, Rolls-Royce implemented ESI ProCAST as part of a digital first co-design workflow to check castability and anticipate casting issues for aerospace cast parts. The deployment centered on applying ESI ProCAST capabilities within design and casting engineering teams in the UK, aligning simulation output with supplier co-design interactions to accelerate design-to-production for cast components.
ESI ProCAST, a 2D/3D Simulation application, was configured to perform castability assessments including mould filling analysis, solidification and thermal simulation, and porosity and defect mapping to inform early design decisions. Simulation runs were embedded into the design review cadence to provide virtual try-outs and defect localization prior to physical pattern validation, reducing the need for iterative physical test castings.
Operational coverage focused on aerospace cast components and involved design engineering, casting engineering, and supply chain partners in coordinated co-design sessions. The implementation emphasized a digital first validation gate where simulation results guided tooling and process parameter discussions with suppliers, creating a repeatable virtual inspection workflow across the component lifecycle.
Governance shifted toward simulation-driven signoffs in the cast part development process, with ESI ProCAST outputs used as documentary evidence for castability decisions and supplier alignment. The UK-based team reports locating approximately 97% of potential casting issues quickly, which reduced physical try-outs and accelerated the design-to-production timeline for cast components.
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Wall Colmonoy United Kingdom | Manufacturing | 195 | $50M | United Kingdom | ESI Group | ESI ProCAST | 2D/3D Simulation | 2016 | n/a |
In 2016, Wall Colmonoy United Kingdom began using ESI ProCAST to simulate investment and sand casting processes at its UK operations. ESI ProCAST was deployed as a 2D/3D Simulation application to enable virtual prototyping of mold filling, solidification and thermal cycles, bringing simulation into iterative engineering workflows for casting design validation before physical melts.
The implementation embedded virtual prototyping into foundry engineering and production planning, reducing the need for physical trial melts and enabling tighter process control and faster speed to manufacture. Wall Colmonoy United Kingdom integrated ESI ProCAST outputs into quality assurance and production decision making, and the use of ESI ProCAST 2D/3D Simulation supported delivery of higher quality precision cast components and the companys expansion into new markets.
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