We are in charge of improving the overall system for and accuracy of TopCAST, the casting CAE that supports gigacasting, the next-generation casting technology.
Toyota Motor Corporation

- Company name
- Toyota Motor Corporation
- Address
- 1 Toyota-Cho, Toyota City, Aichi Prefecture
- URL
- https://global.toyota/en/
- Industry
- Motor vehicle production and sales
- Number of employees
- Over 70,000
- Challenges Facing Customer
- Interview Movie
- History of Use
- Benefits of Introduction
- Future Expansion and Outlook
- Messages From the Person in Charge
Challenges Facing Customer
TopCAST uses a computer to help predict the occurrence of casting defects in advance and optimize casting design plans. Casting CAE has been used by the Toyota Group for over 30 years. However, going forward, even more flexible and speedy design will be essential in the development of high value-added products, as exemplified by gigacasting.
Our Aim
We will feed the manufacturing knowledge of the Toyota Group, including Toyota Motor Corporation, back into TopCAST and work to further improve the technology. Toyota Systems hopes to further accelerate product development by supporting the improved accuracy and continuous overall improvement of CAE from a computational perspective.
Interview Movie
History of Use

Raw Material Development Div.
Production Engineering Development Center
Die Casting Engineering Dept.
Assistant Manager
Takeshi Katsuma
Cost and development time reduced significantly with CAE, which aids the optimal design of casting processes
TopCAST, which can build in quality in advance during the development process of cast products, is a casting CAE that specializes in designing rough materials and casting methods, designing mold cooling, and examining manufacturing conditions to achieve both product functionality and castability. By speeding up the review cycle before prototyping, the design time and rework during prototyping can be reduced, which is essential for improving product and process design efficiency.
In order to utilize CAE, it is necessary to continuously train CAE. We have been working to improve prediction accuracy for more than 30 years. We have able to reduce the number of evaluations and reduce both cost and time significantly by building in quality in advance through reviews using TopCAST.
Benefits of Introduction

Feeding manufacturing knowledge back into TopCAST also leads to human resource development.
CAE is not just something to use; how its accuracy is improved by feeding manufacturing knowledge back into CAE, and how the improved CAE is utilized to further improve quality and shorten development time is important.
Toyota Systems has a site where manufacturing knowledge is condensed, and we can perform data measurement, analysis, and mechanism elucidation all at once. In order to further improve prediction accuracy, it is necessary to understand physical mechanisms and feed them back into CAE correctly. Working together with all team members to consider and proceed with a series of tasks such as measuring data on-site, analyzing and considering it, and quantifying it in order to feed it back into TopCAST not only trains the system but also helps develop important human resources.
Future Expansion and Outlook

Our aim is to train TopCAST together to further accelerate Japanese manufacturing.
In the future, the Japanese manufacturing industry will need to further promote DX utilizing digital tools and shift to a lean way of working and manufacturing, as exemplified by model-based development.
CAE is becoming increasingly important as a tool for DX. It can be very effective in shortening the development period of high value-added products, such as the die-cast integrated structures for structural car body parts, as exemplified by our company's gigacasting.
In the future, TopCAST will need further functional enhancements, such as the use of AI in CAE data analysis. We would like Toyota Systems to incorporate the latest information and application methods into TopCAST in a timely manner so that we can work together to train TopCAST.
Messages From the Person in Charge

Simulation System Division
Development Group 3
Assistant Manager
Kodai Yoko
Since its inception over 30 years ago, TopCAST has supported the Toyota Group in manufacturing. By visualizing the casting process and supporting the review of countermeasures through casting CAE simulations, TopCAST has contributed to not only reducing costs and shortening development periods but also improving product quality.
Recently, as exemplified by gigacasting, products are becoming thinner and larger, and the level required for cast CAE is increasing. We will focus not only on improving the accuracy and speed of TopCAST but also on improving the user interface. And we will continue to accurately feed knowledge gained from manufacturing sites back into TopCAST. By doing so, we hope to transform TopCAST into a CAE that will support Japan’s manufacturing industry in the future.