ESI released the new version of its Casting Simulation Suite — ProCAST and QuikCAST — offering several improved product functionalities. The 2010 version allows engineers to build step-by-step necessary functionalities to span the entire foundry process, from die design through the component's performance during its productive life. Important developments in micro modeling allow the prediction of the microstructure and assessment of the consequent mechanical properties of ferrous and non-ferrous alloy, both as cast and after heat treatment. This breakthrough allowed precise selection of heat treatment parameters in order to obtain the required properties for Austempered Ductile Iron (ADI) components. A new optimization module provides several simulations of the same process, run automatically with slight variations of the input parameters. Robustness and part quality are quantified from the simulation results. The Casting Simulation Suite 2010 also includes solutions and enhancements in gas porosity predictions, pin squeeze, air entrainment, thermal modulus, and results extraction.