For well over a decade, Almex USA Inc. has been supplying hard alloy casting technology to the aluminum industry. Today, customers on five continents produce 2000 and 7000 series aluminum billets using this technology in sizes ranging from 75mm through to 1080mm in diameter. In order to produce such a range of sizes in hard to cast alloys and to aerospace standards, Almex has imparted complete casthouse process understanding and know-how, along with equipment supply to its customers. This paper provides an overview of Almex’s hard alloy casthouse technology and describes some of the critical parameters which must be controlled throughout the process route in order to produce defect free alloys for forging, extrusion and flat rolled applications. Explanation is also made of the microstructural requirements of the as cast product and how these influence the final product; along with the range of quality control solutions supplied by Almex to ensure these requirements are met on a continuous and repeatable basis by Almex’s technology users.