A safety-critical aluminum part was converted from an I-beam weldment to a thin-wall box section using the semi-permanent mold casting process for better structural torsional rigidity, higher load-bearing capacity, and reduced weight. The EVEOOK for Ballantyne Gear was created to help roofers avoid injury from falls. The company enlisted Carley Foundry (Blaine, Minnesota) to produce the invention in A356, an expensive and easy-to-use alloy. This semi-permanent mold casting method offers excellent surface finish and dimensional tolerances compared to sand casting and generally better properties due to higher cooling rate for the same section thickness.

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