The continuous rheoconversion process (CRPTM) is a novel slurry-on-demand process that was developed at MPI/WPI in 2002. The process is based on a passive liquid mixing technique in which the nucleation and growth of the primary phase are controlled using a specially designed “reactor”. The reactor provides heat extraction, copious nucleation, and forced convection during the initial stage of solidification, thus leading to the formation of globular structures. This paper presents our recent work on the scale-up of the CRPTM for industrial applications. In Part II of this paper, we present salient results on alloy optimization via thermodynamic simulations, as well as validation results obtained from industrial Beta trials.