After building specialized Colt SAA’s and obtaining significantly greater power from the .45 Colt, Dick Casull realized that a totally new gun and cartridge were necessary to reach the power level that he envisioned. In 1957 he designed and constructed, from a block of 4140 steel, the first .454 Casull revolver, but it was not until 1983 that the patented Freedom Arms Model 83 revolver so chambered appeared. Built with exacting specifications, line bored chambers and state of art heat-treating methods, the new revolver proved extremely strong, accurate and durable. Additional companies have offered guns and today the .454 is an industry standard cartridge with a maximum average pressure limit of 65,000 psi.

It is important to use dies that correctly size cases, then neck expand to obtain a tight bullet to case fit. Cases should be heavily crimped to obtain correct powder ignition and prevent bullets from "walking" out of the case. Small rifle magnum primers are suggested to aid in ignition. Some makes of cases that have been fired several times with full-power loads, tend to develop loose primer pockets, which should be discarded for safety reasons. In spite of its name, the .454 is standardized with .452-inch bullets. Bullets with thin jackets and soft lead cores designed for .45 Colt pressures will develop increased pressures when compared to bullets that are designed specifically for the .454 that feature a thick jacket and often have alloyed cores.