Parameters specifying properties of the materials used in the lost foam casting process are input at an input step. Numerical methods may be used to simultaneously solve a set of coupled equations relating thermal properties, flow properties, and other physical properties of the metal and foam. A profile number .OMEGA. and an engulf number E may be evaluated using the values of physical quantities determined during the numerical solution step. Once values for the profile number .OMEGA. and engulf number E have been determined, these values may be checked to see if they lie within appropriate ranges.