<p>Automotive structure lightweighting is becoming increasingly important especially for electric vehicles to improve driving range. Aluminum shape castings offer effective lightweighting solutions because of their low density and high flexibility in product design and structural integration in comparison with steel parts. The aluminum casting processes are very complex and challenging, particularly for large integrated multi-functional castings. This requires not only good alloy selection and casting design but also optimal casting and heat treatment process control to achieve the desired material properties and product performance. One of the most effective ways to develop high integrity aluminum castings is through exploitation of virtual casting computational tools. This paper reports the advancement and implementation of multi-scale computational tools for virtual cast component development (VCCD) at GM using an integrated computational materials engineering (ICME) approach from an atom to auto. The VCCD tools have been extensively used for robust design of aluminum shape castings.</p>