Lost foam casting parts as per customized requirements and engineering services

Lost Foam Casting, also known as Full Mold Casting, or Cavityless Molding Casting, refers to a casting method that combines foam molding with dry sand molding. The molten metal directly fills and replaces the space occupied by the original plastic mold, and directly obtains the required casting after cooling. The foam pattern is directly vaporized during the metal casting process, so the lost foam casting does not require mold removal. During the lost foam casting process, the lost foam casting foundry usually the polystyrene as the pattern materials.

▶ Raw Materials Available for Lost Foam Casting (LFC)

Carbon Steel: Low carbon, medium carbon and high carbon steel from AISI 1020  to AISI 1060.

Cast Steel Alloys: ZG20SiMn, ZG30SiMn, ZG30CrMo, ZG35CrMo, ZG35SiMn, ZG35CrMnSi, ZG40Mn, ZG40Crvv, ZG42Cr, ZG42CrMo...etc on request.

Stainless Steel: AISI 304, AISI 304L, AISI 316, AISI 316L and other stainless steel grade.

Brass & Copper.

Grey Cast Iron, Ductile Cast Iron

Other Materials and Standards on request

▶ Capabilities of Lost Foam Casting
Max Size: 1,000 mm × 800 mm × 500 mm

Weight Range: 0.5 kg - 100 kg

Annual Capacity: 2,000 tons

Tolerances: On Request.

▶ Main Steps of Lost Foam Casting
During lost foam casting process, the sand is not bonded and a foam pattern is used to form the shape of the desired metal parts. The foam pattern is "invested" into the sand at the Fill & Compact process station allowing the sand into all voids and supporting the foam patterns external form. The sand is introduced into the flask containing the casting cluster and compacted to ensure all voids and sapes are supported.
Mold foam pattern making.

Age pattern to allow dimensional shrinkage.

Assemble pattern into a tree

Build cluster (multiple patterns per cluster).

Coat cluster.

Foam pattern coating.

Compact cluster in flask.

Pour molten metal.

Extract cluster from flasks.

▶ How We Inspect Lost Foam Castings
Spectrographic and manual quantitative analysis

Metallographic analysis

Brinell, Rockwell and Vickers hardness inspection

Mechanical property analysis

Low and normal temperature impact testing

Cleanliness inspection

UT, MT and RT inspection

▶ Post-Casting Process
Deburring & Cleaning

Shot Blasting / Sand Peening

Heat Treatment: Normalization, Quench, Tempering, Carburization, Nitriding

Surface Treatment: Passivation, Andonizing, Electroplating, Hot Zinc Plating, Zinc Plating, Nickel Plating, Polishing, Electro-Polishing, Painting, GeoMet, Zintec.

Machining: Turning, Milling, Lathing, Drilling, Honing, Grinding.

▶ Why You Choose RMC for Custom Lost Foam Casting Parts?
Greater design freedom in the construction of cast parts

Small quantity is possible due to the layered structure of the pattern.

Lower need for secondary machining with near net shape.

High flexibility by short start up lead time.

Longer EPS mould span life, thus lower average tool costs

▶ General Commerial Terms
Main workflow: Inquiry & Quotation → Confirming Details / Cost Reduction Proposals → Tooling Development → Trial Casting → Samples Approval → Trial Order → Mass Production → Continuous Order Proceeding

Leadtime: Estimatedly 15-25 days for tooling development and estimatedly 20 days for mass production.

Payment Terms: To be negotiated.

Payment methods: T/T, L/C, West Union, Paypal.