Utilization of gamma titanium aluminide alloys in aerospace and automotive/industrial applications has placed significant demand on melters of these materials for products to be used in cast, wrought, and direct-machining applications. There is also a growing demand for input stock used in gas atomization of powders. Current technologies used in ingot manufacturing include plasma arc melting, vacuum arc melting, and induction skull melting + centrifugal casting. Subsequent processing may include forging, re-melting + casting, or machining directly into components. Over the past four years, Alcoa Titanium & Engineered Products (ATEP) has developed a robust melting method using plasma cold-hearth melting technology, including the design and implementation of a new 3-torch system being utilized for production of Ti-48-2-2 cast bars. General discussions concerning plasma cold-hearth melting, manufacturing challenges, and metallurgical attributes associated with cast Ti-48-2-2 ingots will be reviewed.