The quality of a cast part depends upon the complex interaction of phenomena - fluid flow, solidification, heat transfer and stress-strain. In order to obtain desired properties an expert foundry engineer will control several parameters, such as, parting line, sprue location and size, runner and ingate systems, risers, chills, metal flow rate, pouring temperature etc. In the current work we have utilized expert system technology to capture heuristics used in controlling these parameters in sand casting of aluminum alloy parts. The resulting computer system mimics the understanding of a foundry expert and qualitatively / quantitatively recommends the process control parameters. In this work a casting is divided into various conceptual regions called `features' and the process design parameters are determined based on the attribute values of the features. This system is intended to support the experienced foundryman in designing the manufacturing process and to help the novice foundryman by serving as training tool. The computer system is evaluated for several test cases.