ALEXSYS is an intelligent diagnostic tool designed for reducing waste in the Aluminium high pressure die-casting industry. Many expert system shells were investigated to ensure that the most appropriate shell was chosen. The system was divided into two separate components, the Adviser and the Predictor system; one to offer advice regarding dies already in production and the other to offer optimum values for dies in the design stage. Two knowledge sources were used; one a research consultancy and the other a foundry. The system was designed to reflect the sub-sets of knowledge within the foundry. The construction of the pictorial library is described and several screens are shown. A small scale validation on a vane handle has been performed.