INTECO melting and casting technologies is planning and designing a plant for production of a titanium-iron-manganese alloy (TiFeMn) in the form of metallic flakes. Part of this plant is the casting wheel, on which the molten alloy is cooled and solidified using thin strip casting process. The metal strip is then crushed and further utilised as a hydrogen storage medium. The casting wheel is cooled by passing cooling water under the surface of the shell. A literature research was carried out in order to work out the factors influencing the process and the cooling behaviour. A basic simulation model was created in COMSOL Multiphysics, which was used to simulate the heat transfer and the cooling behaviour of the melt. In addition, the thermal stress in the casting wheel was modelled. The shape and material of the casting wheel shell and the properties of the cooling water were identified as factors influencing the casting process. Based on this, an assembly of the casting wheel was designed, whereby the casting wheel shell was designed as a removable sleeve on the wheel body. The relevant components were dimensioned and the assembly was subjected to a simulation of the mechanical load.