In this study, it was observed that solidification simulation enables visualization of the progress of freezing insidea casting and identification of the last freezing regions or hot spots. This facilitated the optimized placement anddesign of feeders with improvement in yield by 15 % while ensuring casting soundness without expensive and time-consuming trial runs. In this case, the thick portion of the component was subjected to shrinkage porosity. It was theroot cause for the poor strength which was leading to premature failure of the component. Proper design of gatingsystem has immensely helped in achieving the directional solidification leading towards the feeder; thereby solvingthe problems of premature failure due to junction solidification and incomplete fill due to sudden variations inthickness.