Because the pipeline area of titanium alloy castings is prone to porosity defects and uneven wall thickness, the gating system was optimized and iterated in multiple rounds from the perspectives of adding process holes, increasing the number of auxiliary castings, and optimizing the runner structure. The optimized gating system was simulated and verified via ProCAST numerical simulation software. The simulation results show that the metallurgical quality in the pipeline area has significantly improved, and the number of hollow defects, such as shrinkage cavities and porosity, has significantly decreased. In addition to optimizing the gating system, the production process is also optimized from the perspectives of shell preparation technology and welding fixtures. The optimization results reveal that the probabilities of loose defects and uneven wall thickness in the pipeline area decrease from 73% and 85% to 2% and 3%, respectively. This confirms the accuracy of the simulation results, validates the effectiveness and feasibility of the optimization scheme, and demonstrates  its ability to meet actual production requirements.