Method based on production of a finite element model of a casting from a CAD representation that is then converted into a final mould 3D representation by building up a mold model of finite elements from a base of the CAD representation until a mold of the desired shape and thickness is obtained Process has the following steps: (1) measurement and determination of the actual surface geometry of the casting in the form of a base mesh of surface elements joint together by nodal points (2) generation of as near as possible approximation of the actual surface using a mesh of either volume or surface Finite Elements (3) determination of nodal points for these elements (4) generation of mould vectors perpendicular to the mold nodal points whose length is proportional to the curvature of the mold at that point and whose separation is equal to the distribution of nodal points and whose combination forms a first stage mold (5) iterative repetition of production of mold generation vectors until the desired surface volume elements are generated and a mold of the desired thickness
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