Twin-roll strip casting is a concerned technology for economically producing magnesium alloys sheets. In this paper, numerical simulation of the twin-roll strip casting of an AZ61 magnesium alloy was carried out and the optimal process parameters were obtained. Then, under the conditions obtained through simulation, AZ61 strips of good surface quality were successfully manufactured. The microstructure of the alloy by twin-rolled strip casting is obvious refined compared with that by conventional casting. © (2014) Trans Tech Publications, Switzerland.