Abstract: Die ca sting process is one of the widely used processes in the manufacturing area. It has the capability for high production rate s with good strength, high quality part s with complex shape s. Die is the main factor which affect s the cost of this process. Even when the process is semi or fully automated the cost of the die is proportionately high. Commercially available FEA Software (LUSAS) has been u sed. A full Finite Element Analysis was carried out in order to achieve an optimum de sign, and to predict the die life. The analysis has been repeated several time s for different element s to achieve the best possible de sign. Since ca sting is a repetitive manufacturing process, fatigue load was taken into consideration and analysis carried out for a high number of cycle s.