Shaped castings, as a manufacturing process, dates to antiquity. However, the art of metal casting has increasingly become a science with the application of empirical methods. Constantly improving old processes or developing innovative processes substantiate the agility of metalcasting to continually meet evolving manufacturing requirements. For example, the lost foam process is meeting the challenge to produce engine blocks with high dimensional tolerance, smooth surface finish, and multiple complex internal passages. This paper explores the fruits of new developments that give designers unparalleled opportunities to apply casting processes to economically produce innovative designs with high integrity.