The Automotive market for designing and manufacturing of plastic intake manifolds in 1994 was kick started by the first large scale lost core part in N. America, the Dodge Neon. Because of the launch timeframe and the novelty of the technology in N. America this was based upon a lost core cell installed in the Siemens Windsor plant, and built as a “turn key” operation from a European injection molding machine supplier. Deliveries from that cell were over 200,000 parts by the end of 1994. Further developments of the plastic manifolds have resulted in growth to a projected annual of 2,000,000 deliveries in 2001 from the same “home base” plant. This spectacular growth has fueled a rapid development of design and manufacturing processes, cell design, in lost core with parallel developments in shell designs and processing. This paper discusses the growth of the lost core design / development activities and references some of the shell parallels.