Based on the theory of electromagnetic field, a physical and mathematical model for electromagnetic continuous casting has been established. The distribution of electromagnetic field in crystallyzer was obtained by measuring magnetic flux density under different powers with small coil method. The effect of processing variables on ingot surface quality was investigated. The forming experiment of Al alloy in electromagnetic continuous casting was conducted. The influence of inductor position and distance between inductor and crystallyzer on magnetic flux density and distribution in the system were simulated by finite element method. It was found that the maximum value of magnetic flux density was located in the center of the inductor and the magnetic flux density was reduced obviously with distance increase between inductor and crystallyzer. The distance of 5～10 mm was favorable to electromagnetic continuous process. It was showed that proper design of the electromagnetic continuous casting system would be favorable to realize well distributed magnetic field and to improve power efficiency. Determining appropriate technological parameters can ensure the electromagnetic continuous casting sucessfully and can be helpful to improve the quality of the ingot.