The paper presents a new knowledge and experiences with verification and optimization of production technology of heavy slab ingot weighing 40 t from tool steel using the results of numerical modelling and of operational experiments at a steel plant in the company VITKOVICE HEAVY MACHINERY a.s. The final porosity, macrosegregation and the risk of cracks were predicted. Based on the results, the slab ingot can be used instead of the conventional heavy steel ingot. Also, the ratio, the chamfer, and the external shape of the wall of the new design of the slab ingot was improved, which enabled to reduce production costs while the internal quality of steel ingots was still maintained at very high level.
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