Abstract: A process for casting metals is disclosed wherein a thin refractory lining is formed between a pattern half and a permanent backup plate. For each desired casting, two mating backup plates are provided; each having portions corresponding roughly to the desired configuration of the casting. A pattern half is aligned against each backup plate so that a thin space along the plate - pattern interface is formed. A bondable refractory material is blown into this space and caused to set by heating or the addition of reactants or catalysts thereto. Each pattern half is then removed from the backup plate assembly and the lined, mating backup plates are assembled together so as to form a lined mold cavity therebetween. The desired molten metal is then poured into the cavity. After the casting is cooled, the refractory is stripped from the backup plates and the backup plates are recycled for further use.