Lost Form Casting Procedure

1

Lost Foam Casting Process

Full Automatic Plant

Lost Foam Casting Plant
FULL AUTOMATIC PLANT

Lost foam casting is an evaporative-pattern casting process that uses foam patterns (typically expanded polystyrene EPS) to create complex metal components.

The foam pattern is coated with refractory material, placed in a sand mold, and molten metal is poured in.

As the metal fills the cavity, the foam evaporates completely, leaving behind a precise metal replica of the original pattern.

2

Lost Foam Casting Process Flow

8 Step Manufacturing Process

Create Foam Pattern

1. Create Foam Pattern

Coat with Slurry

2. Coat with Slurry

Add Sand in Flask

3. Add Sand in Flask

Compact the Sand

4. Compact the Sand

Pour Molten Metal

5. Pour Molten Metal

Foam Pattern Burns Away

6. Foam Pattern Burns Away

Metal Fills Cavity

7. Metal Fills Cavity

Remove Casting

8. Remove Casting

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Key Advantages

Benefits of Lost Foam Casting

Design Freedom – Enables production of highly intricate shapes that are difficult with conventional casting.

High Precision – Delivers excellent dimensional accuracy and smooth surface finish.

Cost Efficiency – Eliminates cores and reduces machining requirements.

Material Saving – Minimizes waste compared to traditional casting methods.

Versatility – Suitable for ferrous and non-ferrous metals.

4

Applications

Industries We Serve

Automotive – Engine blocks, cylinder heads and manifolds.

Industrial Machinery – Pump housings, valve bodies and intricate assemblies.

General Engineering – Prototype casting, artistic casting and custom parts.

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Plant Capacity Details

Full Automatic Plant Models

Model No. Capacity (Ton/Day) Require Space (M²) Power (Kw.) Plant Height (M.)
CFLF1 5 1020-1360 400-520 10-12
CFLF2 10 1650-2200 900-1100 10-12
CFLF3 20 2900-3600 1800-2100 10-12
CFLF4 50 8600-10700 4900-5100 10-12

Note: In table space and power include whole plant (raw material to finishing).