The U.S. Department of Energy, Metal Casting Industry of the Future (IOF) facilitates partnerships between industry, academia and laboratories to address critical research needs facing the casting industry. One example of the success of this approach is Lost Foam Casting. The Lost Foam process has significant cost and environmental advantages including allowing designers to reduce machining, consolidate parts and minimize assembly operations while reducing solid waste and emissions. It also allows metal casters to reproduce complex curves and shapes that are often difficult with other methods. The advantages of the Lost Foam Casting Process had not been fully realized due to a lack of knowledge of the process needed to exercise proper control measures.