Published Article / Numerical modelling has successfully been used as an efficient tool to convert a gravity cast brake calliper to a thixocasting process. The thixo-module of Procast has been used for the modelling process to obtain optimum processing parameters. Results from interrupted shot castings show excellent correlation with the fluid dynamics and flow pattern of the model. The level and location of porosity revealed by non-destructive X-rays and microscopic analyses showed good correlation with the model prediction.