I had seen a pic of an out-of-battery kaboom (high primer?) and naturally, a severly damaged rifle. And the guy said, see, it was a cast lower and it is all messed up. Well, truth be known, a forged would have been just as damaged.
I have heard of a few cast lowers cracking due to a casting flaw. But I am sure any mfg would replace such a lower.
Olympic Arms HAD some MACHINING problems with their cast lowers, holes not drilled correctly, as I understand it. But it was not due to the fact it was cast. They corrected the problem, and their current cast lowers are fine.
I think all of the Essential Arms lowers were cast, I know all the ones I have seen were. And no one I have talked to has had any problem with them. They were cast by Ruger (no not a rumor), who really have investment casting for firearms down pat. BTW, Essential made most of their lowers (and matching uppers) with the gray moly finish like the old original M16's. They had both A1 and A2 uppers available.
However, if any of you feel the urge to replace your cast lowers with forged, I would be glad to accept the old cast lowers and see they are disposed of properly.