Lost Foam Foundry

Lost Foam Process is similar to Lost Wax (Investment casting) process.

First a foam pattern is moulded using Expandable Polystyrene (EPS) or co-polymer which is an exact replica of the desired casting. Runners and risers are attached by glue to the foam pattern and a cluster is made of one or more number of foam patterns. The cluster is then coated with a permeable refractory slurry coating in a homogenous bath by dipping.

The dry coated cluster is invested in a flask by sand, then vibrated to compact the sand around the cluster in the flask. Molten metal is poured through the pouring cup into the foam cluster. The molten metal replaces the foam which gets evaporated. On solidification of the metal, the sand is drained off the flask and the tree is removed. The castings are knocked out from the metal cluster, fettled and finished before they are shipped out.