with the development of computer technology, foundry CAE technology has made rapid progress. Commercial software packages of casting process simulation, therefore, have become more and more practical. This paper introduces both the recent developments and some applications of InteCAST software, a commercial numerical simulation software package for foundry industry, with more than 120 customers all over the world. The function modules of InteCAST8.0 and some new techniques, such as uneven mesh technology for mold filling simulation and numerical mouse technology for data visualization, were introduced. Several applications on special castings such as investment casting, low pressure die casting, and high pressure die casting, were given. These applications showed that the software can help engineers to optimize casting process by forecasting casting defect.