Waste: an unwanted or undesired material or substance (Wikipedia: online encyclopedia). To an outsider, looking in at the metalcasting industry, it seems as though the substances we waste most often are time and energy - and they might well be right! At some foundries, these non-replaceable resources are squandered - not recklessly, not intentionally - but because their design and production methods are based on outdated production processes. Past Engineering Process In times past, paper and pencil were the most important tools a casting designer had - and the development of a casting was a process that was tedious and time consuming. A paper design was created; the blue print was introduced to the die caster - who teamed up with a toolmaker. Together, a die-casting machine was selected; the process and mold layout developed and costs estimated. Quotations were made. The bidding winner gave permission to his tool vendor to order die steel and start with mold designing. When finished, t...