An MCP (Model Context Protocol) server that enables AI agents like Claude to interact with OpenFOAM for foundry casting and metallurgical simulations.

• 12+ Foundry-Specific Tools for AI agents
• Automated Case Setup for different casting types
• Material Database with properties for common metals and mold materials
• Defect Prediction (porosity, shrinkage, hot spots, cold shuts, misruns)
• Parametric Optimization for gating systems
• Multi-Physics Support (mold filling, solidification, heat transfer)
• Parallel Execution support for faster simulations

• Python 3.10+
• OpenFOAM v11 or later (v2306, v2312, etc.)
• Claude Code or other MCP-compatible client

• ParaView for visualization
• PyFoam for advanced OpenFOAM file parsing
• Multi-core CPU for parallel simulations

# Add OpenFOAM repository
sudo sh -c "wget -O - http://dl.openfoam.org/gpg.key | apt-key add -"
sudo add-apt-repository http://dl.openfoam.org/ubuntu

# Install OpenFOAM
sudo apt-get update
sudo apt-get install openfoam11

# Source OpenFOAM environment
source /opt/openfoam11/etc/bashrc

# Add to your ~/.bashrc for persistence
echo "source /opt/openfoam11/etc/bashrc" >> ~/.bashrc

docker pull openfoam/openfoam11-paraview512

# Clone repository
git clone https://github.com/yourusername/openfoam-mcp.git
cd openfoam-mcp

# Create virtual environment
python -m venv venv
source venv/bin/activate  # On Windows: venv\\Scripts\\activate

# Install package
pip install -e .

# Or install dependencies directly
pip install -r requirements.txt

Add to your ~/.claude/mcp.json:

{
  "mcpServers": {
    "openfoam": {
      "command": "python",
      "args": ["-m", "openfoam_mcp.server"],
      "env": {
        "FOAM_INST_DIR": "/opt/openfoam11"
      }
    }
  }
}

# Using Claude Code CLI
claude-code

# Then ask Claude:
> "Create a mold filling simulation for an aluminum casting at 750°C with a sand mold"

# Claude will:
# 1. Create the case
# 2. Set up geometry
# 3. Configure material properties
# 4. Generate mesh
# 5. Run simulation
# 6. Analyze results for defects

• Mold Filling: Gravity pour, low-pressure, high-pressure
• Solidification: With heat transfer and phase change
• Continuous Casting: Steel, aluminum continuous casting
• Die Casting: High-pressure die casting

Metals:

• Steel (carbon steel)
• Aluminum (pure and alloys)
• Iron (cast iron)
• Copper
• Bronze

Mold Materials:

• Sand
• Ceramic
• Metal (permanent mold)
• Graphite

# Claude command:
"Create a solidification simulation for steel at 1650°C in a sand mold named steel_casting_01"

# Option A: From STL file
"Set up geometry for steel_casting_01 using the STL file at /path/to/casting.stl with fine mesh"

# Option B: Parametric
"Set up a simple box geometry for steel_casting_01: 0.2m x 0.15m x 0.1m with medium mesh"

"Run the simulation for steel_casting_01 using interPhaseChangeFoam for 100 seconds"

"Analyze steel_casting_01 and predict all defects"

"Optimize the gating system for steel_casting_01 to minimize porosity"

┌─────────────────┐       MCP Protocol        ┌──────────────────┐
│   Claude AI     │ ←──────────────────────→  │  OpenFOAM MCP    │
│                 │                            │     Server       │
└─────────────────┘                            └──────────────────┘
                                                        ↓
                                               ┌──────────────────┐
                                               │  API Managers    │
                                               │  - OpenFOAMClient│
                                               │  - CaseManager   │
                                               │  - ResultAnalyzer│
                                               └──────────────────┘
                                                        ↓
                                               ┌──────────────────┐
                                               │  Case Builders   │
                                               │  - Templates     │
                                               │  - Material DB   │
                                               └──────────────────┘
                                                        ↓
                                               ┌──────────────────┐
                                               │  OpenFOAM Core   │
                                               │  (Solvers)       │
                                               └──────────────────┘

# Run all tests
pytest

# Run with coverage
pytest --cov=openfoam_mcp --cov-report=html

# Run specific test
pytest tests/test_case_manager.py

openfoam-mcp/
├── openfoam_mcp/
│   ├── __init__.py
│   ├── server.py              # Main MCP server
│   ├── api/
│   │   ├── __init__.py
│   │   ├── openfoam_client.py  # OpenFOAM command execution
│   │   ├── case_manager.py     # Case creation/management
│   │   └── result_analyzer.py  # Result analysis
│   ├── builders/
│   │   ├── __init__.py
│   │   ├── case_builder.py     # Case file builder
│   │   └── templates.py        # OpenFOAM file templates
│   └── utils/
│       └── __init__.py
├── tests/
│   ├── test_server.py
│   ├── test_case_manager.py
│   └── test_openfoam_client.py
├── examples/
│   ├── simple_mold_filling.md
│   └── solidification_analysis.md
├── docs/
│   ├── getting_started.md
│   └── tool_reference.md
├── pyproject.toml
├── requirements.txt
└── README.md

• FOAM_INST_DIR: OpenFOAM installation directory (default: /opt/openfoam11)
• OPENFOAM_RUN_DIR: Directory for simulation cases (default: ~/foam/run)

You can extend the material database by editing openfoam_mcp/builders/case_builder.py:

self.metal_database["my_alloy"] = {
    "density": 8000,
    "viscosity": 0.005,
    "thermal_conductivity": 40,
    "specific_heat": 500,
    "liquidus_temp": 1700,
    "solidus_temp": 1500,
    "latent_heat": 250000
}

Contributions welcome! Please:

1. Fork the repository
2. Create a feature branch (git checkout -b feature/amazing-feature)
3. Commit your changes (git commit -m 'Add amazing feature')
4. Push to the branch (git push origin feature/amazing-feature)
5. Open a Pull Request

• Add more casting types (investment casting, centrifugal casting)
• Implement real-time progress monitoring
• Add machine learning-based defect prediction
• Support for more OpenFOAM solvers
• Integration with commercial casting software for validation
• Web-based visualization interface
• Automated gating system design
• Multi-objective optimization

• Mesh generation for complex geometries may require manual snappyHexMesh tuning
• Large simulations (>1M cells) require parallel execution
• Temperature-dependent material properties not yet implemented

• OpenFOAM User Guide
• OpenFOAM Tutorials
• CFD Online Forums

• directChillFoam Paper
• OpenFOAM Casting Resources

• Model Context Protocol Docs
• MCP Python SDK

This project is licensed under the MIT License - see the LICENSE file for details.

• OpenFOAM Foundation for the excellent CFD toolkit
• Anthropic for the Model Context Protocol
• The foundry and metallurgy research community

For questions or support:

• Open an issue on GitHub
• Email: your.email@example.com

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