Abstract An analytical model for the optimization of the consumption of materials and energents in a typical copper casting process based on a standard simulation procedure is presented. The proposed microeconomic analysis in correlation with the virtual manufacture of castings enabled a shortening of the time required to develop a product, as well as the fabrication of high quality castings, which could be a crucial contribution to the achievement of increased engineering adequacy and economic competitiveness. In this sense, the article demonstrates the beneficial employment of mathematical programming within a systematic economic analysis. The analyzed casting process is a part of the metallurgical manufacturing operations of the Copper Smelter and Refinery Bor, Serbia.