The Idea

Cast Bore Flutes are Instruments that have a wooden body, but the bore of the instrument is cast into the wood, using a special Resin. There are a lot of advantages:
The bore is very stable and not affected by moisture. Compared to other plastic flutes made from ABS, Acetal, PVC or the likes they are much lighter. Wood that is not usually used for flutes can be used to make an instrument, a rather porous and light timber has even an advantage because the Resin can bond better with the wood by soaking deep into the grain of the wood and locking the resin tight to the wood.
Blow hole and noteholes are cast as well, so the blow or notehole chimney is made from Resin too. The Timber is well protected from moisture and the Cast Bore flute is practically maintenance free. Only the outside of the instrument needs some care, the bore needs only a basic wipe after playing, but even if that's not possible it's not causing any damage.
This System is not only used for the basic student model flute, but also for fully keyed professional instruments. The whole process is not new and is used for example on Wing joints and Boot joints of Bassoons very successfully for years.

The Professional Cast Bore Flute

This type of flute is a fully grown professional instrument. Plain wooden flutes need care to keep them in good condition. The Cast Bore process helps there. The Cast Bore is sturdy, absolutely air- and water-tight and needs hardly any maintenance.
The Flute Head is just like the normal Standard Flute head made with a tuning slide and separate barrel, has the same bore dimensions and head-plug etc.
Here a Cast Bore Standard head in African Padauk: Cast Bore Standard Head in African Padauk
The Body is made in the same way as a wooden Standard or C-Foot body, the only difference is, that the bore is cast into the timber and the noteholes are drilled before the bore is cast, so they are lined too. The rest of the process is the same, except there's no oiling and polishing of the bore necessary of course.
Here a Cast Bore Standard body in African Padauk: Cast Bore Standard Body in African Padauk
C-Foot models are also available, the main body has a second tenon to fit a separate C-foot. Their lowest note is D, if there's no keywork to extend the range and they are in the key of D. The addition of a C-Foot helps to play notes in the third register.
Here is a Cast Bore Standard Middle Joint in Tarara with a Short F-Natural key, Silver-plated: Cast Bore Middle Joint in Tarara with Short F-Natural Key
And the Cast Bore C-Foot of the same flute in Tarara: Cast Bore C-Foot in Tarara
Keywork can be added to Cast Bore Standard Flutes the same way they can be added to wooden flutes, no differences here! Keywork can be added when ordering a flute or later, when the player finds it's necessary to get some keywork to extend the playability of the instrument. All instruments have capped tenons to protect them from cracking.
Here are close up pictures of a foot tenon and main tenon:
Capped Foot tenon on a Cast Bore C-Foot flute in Tarara Capped Main tenon on a Cast Bore C-Foot flute in Tarara

The Timber

Most Timbers can be used to make Cast Bore flutes due to the principle of the Cast Bore. However, because these flutes are also meant to be keyed, I suggest to stick to heavier, denser timber. It is possible to add keywork to a Maple flute though.
Timbers available at the moment are:
African PadaukCast Bore Standard Head in African Padauk
KowhaiCast Bore Head in Kowhai
TotaraCast Bore Head in Totara
MapleCast Bore Head in Maple