Performing the castability analysis of a part and its cost estimation requires substantial knowledge and experience. It is also time consuming and dependent on the expert personnel available. This paper describes the development of an intelligent system for castability analysis and product cost estimation for a permanent-mould casting company. The system allows personnel with little technical knowledge to analyse the part, estimate the cost, and prepare quotations with little or no assistance from an expert whose time is better utilized on high potential quotations and more direct product development activities. © 1998 Taylor & Francis Group, LLC.