The twin-roll casting technology has attracted significant attention in recent years due to its remarkable advantages, including a streamlined process, reduced energy consumption, and minimized emissions. This study focused on optimizing the design of the cooling water channel for the casting roller through a combination of numerical simulations and experimental verification. Research has shown that annular water channels can effectively promote uniform, stable, and efficient heat exchange between the casting rollers and molten pools. Furthermore, the study compared the temperature and thermal deformation characteristics of casting rollers during the casting processes of various metal materials, such as magnesium alloy, aluminum alloy, titanium alloy, steel, and Inconel 718 alloy. The results indicated that transitioning from casting magnesium alloy to Inconel 718 alloy led to a surface temperature increase of over 200 °C on the casting roller, accompanied by a substantial 105 % rise in thermal deformation. Additionally, an investigation of the temperature and deformation distribution across different casting roller materials revealed that replacing steel casting rollers with copper alloy rollers reduced the peak surface temperature by 36 % and decreased the maximum thermal deformation from 408 μm to 298 μm, representing a 27 % reduction. These research findings provide significant practical insights for guiding the structural design of casting rollers and optimizing process parameters in twin-roll casting.