Gelcasting is a near-net-shape forming technique that is applicable to various types of powders. It is accomplished by casting a concentrated suspension of a commercial ceramic powder in a solution of a polymerizable monomer and then polymerizing. The monomer used in the process is acrylamide which undergoes a vinyl polymerization. A filled gel is formed, which is dried and processed further. Gelcasting of alumina, sialon and silicon nitride has been carried out as the principal part of the Oak Ridge National Laboratory (ORNL) program. Two rotors have been gelcast as part of a cooperative research agreement between Allied-Signal Aerospace Company and ORNL. Emphasis is placed on the unit-operations of the process. Because a requirement of the process is a castable suspension of more than 50 vol % solids loading, good dispersion is crucial. Drying, another key process, has been studied extensively. Data on the relationship of physical properties of products to some of the more significant processing variables is discussed. Environmental, safety and hygiene issues are summarized. 9 refs., 7 figs
