Major lessons learned were:

• 3D computer-aided design is the key to rapidly optimizing the design for mechanical performance and weight reduction.  This also reduces the "first part" time. 

• Concurrent engineering by the design team is essential at each step of the design and casting development process for rapid and effective part production.

• Die design for efficient metal yield, smooth metal flow, and controlled solidification is critical to ensure that the casting meets tolerance, mechanical strength, and cost requirements.

• Rapid prototyping was used to check form-fit-function on the final design. Rapid prototyping was done by Global Design Works, using a high speed 3-D printing system.