Numerical simulation of filling and solidification of large aluminum alloy support frame in indirect casting was conducted based on FDM. Based on analysis of simulated results

the rational pouring temperature of 700 ℃

and injected velocity of 10 m/s

are determined. Meanwhile

the die structure and processing design are completed

and the die is made. The origination of casting defects in trial-production of the aluminum alloy support frame is approached. It was found that the gas hole and oxidized slag are dominant in the casting defects. The support frame with high quality and performance can be manufactured by adjusting the proportion of the release agent

and by decreasing the spraying thickness of the release agent and by shortening the cycling time of the squeezing process.