Elkhart Industrial Division of Amcast Industrial Corporation has developed an improved process for manufacturing complex aluminum components for automotive and other applications. This “FORMCAST™” process shares some features of forming, casting, and extrusion. Capabilities of this new process extend beyond conventional processes in its ability to form complex, three dimensional shapes with a high degree of accuracy. Integrity of the material is maintained during forming by ensuring that the material is maintained under pressure during the entire forming process, so that no porosity or voids are allowed to form. Parts are formed in tools designed to produce a precisely machined cavity, so that the repeatability of the dimensions is quite high.This paper will describe the process, present data on the dimensional repeatability of an example part, and data on the properties of various aluminum alloys after being formed. Cost of parts formed by this process will be discussed. Characteristics and capabilities of the process will be compared with existing processes to allow designers and manufacturing engineers to evaluate the feasibility of applying this process in the manufacture of new products and replacements for existing products.