Lost Foam Casting

What Type of Parts are Good Candidates for Lost Foam Casting?

Typical parts created using the lost foam casting process include car parts, marine engines, and many other industrial parts. This process is commonly used for transmissions, engine blocks, and cylinder blocks. Marine engine manifolds are often made with this process as well. Car manufacturers and boat manufacturers around the world utilize these services to cut back on costs and for high efficiency of parts. This process can also be used for light fixtures, sculptures, and other interior decorating products. Lost foam casting ensures that parts will have the same integrity time and time again.

Designing Parts for Lost Foam Casting

There are many different ways to create a pattern for lost foam casting. The key in every process is creating a pattern using polystyrene foam. If simple geometry is used, the pattern can be cut using a hot-wire foam cutter.  Once the pattern is made, it can be mass produced by using a process very similar to injection molding. In this similar process, pre-expanded beads are injected into a mold that is pre-heated at a low-pressure rate. To finish the pattern, premade pouring basins, risers, and runners can be hot-glued to it.

Once the pattern is finished, foam clusters are covered in a refractory coating. Now the surfaces are smooth, and gas can escape safely. Once coating dries, clusters are placed into flasks, and then backed up with unbounded sand. Sand is then compacted with the use of a vibration table. After compaction is complete, the mold is ready to be poured!  Automatic or manual pouring can be used, but automatic is the standard.

Sourcing Lost Foam Casting

You have many options in your search for sourcing with lost foam casting services.