Ceramic dies have been developed to meet the need for a dimensionally stable tool, which can withstand the temperatures (800 to 1750 °F) and high forming pressures (up to 1,000 psi) that are required for SPF, SPF/DB and hot sizing of metal parts. Further, the die matrix has been strengthened in excess of 2000 psi modulus of rupture through the use of integral ceramic reinforcement (re-bar) rods. A plasma spray glaze coating is currently under development that will be used to substantially reduce deterioration of ceramic die surfaces and increase life. With the improvements that have been made to strengthen fused silica based ceramics, the performance of ceramic tools is slowly closing in on meeting the same forming complexity as CRES dies can achieve. Boeing has successfully Superplastic formed jet engine wide chord fan blades using ceramic dies and many production aircraft parts are being built with Boeing’s patented ceramic die technology. The potential advantages of fused silica ceramic dies over steel or CRES dies are: - Cost – ceramic dies are a small fraction of the comparable cost, typically 5-10%. - Lead time – ceramic dies require only 3-5 weeks to build vs. 8-14 months. - Inventory reduction – dies are not stored, they are simply re-cast when needed. - Net shape – no machining or hand blending is needed after casting. - Die surface – RA 16 or better finish. Superplastic Forming and hot forming of titanium is becoming highly attractive option for monolithic structures that must be compatible with graphite-based composites. For many of these applications, the non-recurring cost and lead-time for metal tooling is the most significant factor in the economic trade studies. The current Boeing 7E7 conceptual design features more SPF titanium parts than any other aircraft has considered. Ceramic dies present a viable alternative tooling method for all of these new opportunities and have opened up New Frontiers in manufacturing.