The process begins with the formation of patterns. These patterns are generated from wax by utilizing an aluminum wax injection mold for production lots. Rapid prototype patterns can be generated from CAD models using various resins and polymers.

The wax patterns are attached to runner systems. The runner system chosen and the orientation of patterns on the runner system is specific to each part and will be used to feed metal in to the pattern during the casting process. The wax pattern and runner assembly is referred to as a "tree".

The building of the ceramic shell around the wax patterns and runner system involves dipping the wax tree in a slurry, draining it, and then covering it with a ceramic grain. The process is repeated several time to form a layered ceramic shell around the wax tree.

The removal of wax is accomplished by placing the wax tree encased in ceramic shell in a high temperature and high pressure vessel. The high temperature melts the wax inside the ceramic shell and the pressure forces it to run out through the runner system. Once the wax is melted the ceramic shell is left with multiple cavities of the pattern shape and a runner system leading to each cavities.

The casting of parts is accomplished by pouring molten metal into the preheated ceramic shell. As the metal cools it solidifies into the shape of the cavities left behind in the ceramic shell by the wax patterns.

Once the metal has cooled the ceramic shell material is removed from the castings and the runner system. This is accomplished by mechanically vibrating the tree.

Each individual casting is then removed from the runner system. The runner system is melted again to be poured into other ceramic shells.

The castings are now ready for any secondary operation: grinding, heat treating, straightening, machining, plating, non-destructive testing, and finally shipment to the customer.