Ross and Catherall have a long history in the manufacture of alloys for the automotive, IGT and aerospace sectors. A project was initiated to develop a fully vacuum sealed continuous casting method for the production of superalloys. The process has now been developed to realise the benefits to the investment caster of improved cleanliness, minimal surface defect rectification, significantly reduced contamination through central pipe elimination and increased ingot use weight/length capability. With many alloys now in commercial production, developments are progressing to continuously cast aerospace alloys, including single crystal alloys.