The design of the Metal mold casting should consider several variables such as the material properties and shape of the mold. In particular, the thermal stress generated by the thermal expansion and contraction depending on the thermal gradient of the mold causes partial plastic deformation on the mold, which causes damage or fracture of the cast. Consequently, the thermal deformation along with thermal stress leads to thermal deformation of the cast itself. In this study, the temperature analysis of the cast and mold is simulated by FDM to control the thermal deformation and stress as a result of the thermal gradient of mold. Using the results from FDM simulation, the thermal deformation and stress are analyzed by FEM and, the optimal mold design with minimum thermal deformation of the cast is suggested.