Lost Foam Casting Services
DEZE provides high-quality custom lost foam casting parts and components to a wide range of industries. We also offer a wide range of secondary services including machining, surface treatment, and more.
What Is Lost Foam Casting?
Lost foam casting is a metal casting process that uses an expendable foam pattern to form the shape of the desired casting. The foam pattern is coated with a refractory material, and then the mold is surrounded by unbonded sand. Once the molten metal is poured into the mold, the foam evaporates (hence “lost foam”), leaving behind a perfectly cast metal part that mirrors the original foam shape.
The foam pattern was first used in metalworking in 1958. Although this mold casting technique is not as popular as other methods such as sand mold casting or permanent casting, it maintains outstanding advantages, especially in casting complicated and precise molds.
The Lost Foam Casting Process
The lost foam casting process, similar to investment casting, is a highly efficient method used to produce complex metal parts with precise shapes. Here’s a brief overview of how it works:
1、Pattern Creation
The process begins by creating a pattern made from expandable polystyrene (EPS) foam. This foam pattern is a replica of the final part and is produced either by molding or machining the foam into the desired shape.
3、Coating
The foam pattern is coated with a refractory ceramic material to provide a barrier between the foam and the molten metal. This coating ensures the casting’s dimensional accuracy and surface finish.
5、Pouring
Molten metal is poured directly onto the foam pattern, causing the foam to vaporize. As the foam evaporates, the molten metal fills the void left behind, forming the final shape of the casting.
2、Pattern Assembly
If the part is complex, several foam pieces can be glued together to form a complete pattern. Sprues and gates (channels for the metal to flow through) are also added to the foam pattern.
4、Molding
The coated foam pattern is then placed into a container and surrounded by unbonded sand, which supports the foam and helps maintain the shape during the metal pour.
6、Cooling and Removal
Once the metal has solidified and cooled, the casting is removed from the sand mold. Minimal post-processing is required, as the lost foam method produces smooth, near-net-shape castings.
Lost Foam Casting Materials
At DEZE, we produce complex parts from a wide range of metals. Our team is committed to quality precision casting, and we work with a variety of metals to produce components to your exact specifications. Some precision-casting alloy material options include:
Smooth Surface Finish
The refractory coating applied to the foam pattern helps create a smooth surface finish on the final part, reducing the need for additional surface treatments.
Complex Geometry
One major advantage of lost foam casting is its ability to produce intricate shapes and geometries, including internal cavities, thin walls, and fine details, which are challenging to achieve with traditional methods.
Minimal Machining
The precision of the foam pattern and the quality of the surface finish means that the cast parts require very little finishing work. This reduces the need for expensive post-casting machining processes and lowers overall production costs.
Cost-Effective for Large Parts
This method is especially cost-effective for large parts or high-volume production runs, where the cost savings from reduced machining and material usage add up.
Advantages of Lost Foam Casting
Lost foam casting offers several key advantages that make it a preferred method for producing metal parts with high precision and intricate details.
Custom Lost Foam Casting Parts
DEZE offers lost foam casting services, producing high-quality custom metal components. Utilizing various metals and alloys, we create complex and detailed parts that are both cost-effective and high-performing, designed to meet your specific requirements.
Applications of Lost Foam Casting
Lost foam castings are highly valued across industries due to their ability to produce intricate shapes, smooth surfaces, and precise dimensions. It is especially useful for creating components with internal cavities, thin walls, and complex structures that traditional casting methods struggle to achieve.
Aerospace Industry
such as aircraft frames, landing gear parts, interior components, etc.
Automotive Industry
engine components, transmission cases, wheels, structural components, etc.
Consumer Goods
such as cookware, electronic enclosures, decorative items, etc.
Marine Industry
such as boat fittings, propellers, and marine hardware, etc.
Lost Foam Casting Products Display
At DEZE, we specialize in lost foam casting services for industries such as automotive, aerospace, and manufacturing. Our advanced techniques and equipment ensure precision-cast components that meet your exact specifications. Whether you need intricate parts with complex geometries or high-quality castings for demanding applications, we have the expertise to deliver outstanding results.
