The aim of the project is to develop significantly improved ferroalloy casting ingots with increased service life (N) and reduced material consumption rate. (Ingot weight/quantity of ferro-alloy spilled in the ingot throughout the service life of the ingot [kg/tonne]) by alteration of their structure and material changes. This goal will be achieved thanks to the planned R&D works, carried out in cooperation with the AGH University of Science and Technology, The project is in line with KIS 8 Advanced materials and nanotechnology and meets the horizontal principles of equal opportunities and non-discrimination, the principle of sustainable development and is in line with the 6R principles. The project is in line with the Charter of Fundamental Rights and the Convention on the Rights of Persons with Disabilities. In the current solution, ingot moulds are made in the traditional technology of sand moulds from furan masses, into which grey cast iron is poured. The structure of castings/ingotries is homogeneous as to the compositions throughout the casting volume, and the differences in the structure of the macrostructure are small and result only from the variation in wall thickness and the rate of solidification and cooling of the casting. The design of the ingot box is simple and has the shape of a cuboid box with dimensions ~ 2000 x 1000 and a height of 400mm with a thickened bottom. This arrangement: the design of the ingot mould and the macrostructure of the ingot mould are not conducive to its resistance to thermal shocks and thermal stresses that occur during heating and cooling and mechanical removal of the ferro-alloy ingot. As part of the Project, in addition to work on the optimization of the structure, research will be carried out on the modification of the material structure, which will include a targeted change (fragmentation) of the structure in the side walls of the ingot by modification from active coatings applied to the mold surface. A metal-ceramic structure with a depth of several millimetres and a composite structure will be built into the top/working layer of the bottom, which is subject to the fastest destruction (micro- and macro-cracks). The metal-ceramic structure, due to the nearly 3 times lower temperature conductivity, will constitute a heat barrier, protecting the bottom surfaces from excessive rapid overheating and will reduce the level of temperature differentiation on the bottom cross-section. Changes to the structure will be aimed at lowering the level of maximum thermal stresses, which in the final phase lead to cracking of ingots. It is expected that the synergy effect of structural changes and changes in the structure of the material in individual segments (side walls, bottom) of the ingot plant will allow for a significant (by more than 20%) increase in its lifespan and no less reduction in the material consumption rate by no less than a percentage. The results of the project are a response to the identified technological gap in the cooperation between Krakodlew S.A. and the AGH University of Science and Technology in Krakow. The conducted R&D works will allow the Consortium to file patent applications, and the results will be implemented in the Consortium's business activity. The state-of-the-art analysis confirms that, on a global scale, there is no case for the production of ferroalloy ingots with single or multiple walls with a built-in ceramic-metal (composite) structure. Therefore, the innovation of the planned solution has been demonstrated in this respect of the construction of ingot mills. ReSiCr alloy ingots break in half of the longer side walls (board). Innovative solutions in the Project go in the direction of creating a reinforced structure in these areas by accelerating cooling. Thus, the ingot mill will have a deliberately and controlled heterogeneous structure, which is not achieved in existing casting technologies. This is the second innovation in the technology and properties of ingot casting. The ingots will have a contoured (currently flat) bottom, which will reduce the level of thermal stress, delay the onset of cracks at the bottom, into which the liquid ferroalloy penetrates, making it difficult to separate the ingot from the ingot (breaking out the ingots).