Lost Foam Casting

At Metal Cast Engineering, we offer Lost Foam Casting as an advanced solution for manufacturing intricate metal components with high dimensional accuracy and excellent surface finish. This innovative casting process is ideal for producing complex shapes that would be difficult or impossible to achieve through traditional casting methods.

What is Lost Foam Casting?

Lost Foam Casting (LFC) is a modern metal casting method where a foam pattern (usually made of expanded polystyrene) is used to create the mold. The foam is coated with a refractory material and then surrounded by sand. When molten metal is poured into the mold, the foam evaporates, and the metal takes its place, forming a precise cast of the original design.

Key Features & Advantages

• Complex Geometries: Ideal for casting intricate shapes with internal cavities, undercuts, and fine details.

• Superior Surface Finish: Achieves a smooth and consistent surface, reducing the need for machining.

• Dimensional Accuracy: Produces parts with tight tolerances and minimal shrinkage.

• Reduced Assembly: Allows for casting of integrated components, reducing the need for multiple part assemblies.

• Lightweight Structures: Suitable for producing components with thin walls and lightweight design.

• Cost-Effective Tooling: Foam patterns are relatively inexpensive and quick to produce.

Materials and Applications

We specialize in Lost Foam Casting using a wide range of ferrous and non-ferrous metals, including:

• Aluminum Alloys

• Cast Iron

• Steel Alloys

Common applications include:

• Automotive Parts: Engine blocks, intake manifolds, cylinder heads

• Industrial Machinery: Pumps, housings, brackets, covers

• Agricultural Equipment: Structural and functional parts

• Marine and Aerospace Components

Value-Added Services

To ensure you receive ready-to-use components, we also provide:

• Machining & Drilling

• Surface Treatments: Painting, powder coating, plating

• Inspection & Testing: Dimensional checks, X-ray inspection, and non-destructive testing

• Assembly of Components