Lost Foam Casting Gallery


Sand Processing

Sand Processing


Sand Process

Sand Process


Foam Patterns

Foam Patterns


Foam Patterns

Foam Pattern


Foam Pattern Making

Foam Pattern Making


Pattern Making

Pattern Making


Foam Pattern

Foam Pattern


Foam Pattern Coating

Foam Pattern Coating






Lost Foam Casting vs Vacuum Casting

Description Lost Foam Casting Vacuum Casting
Suitable Castings Small and medium-sized castings with complex cavities, such as engine block, engine cover Medium and large castings with few or no cavities, such as cast iron counterweights, cast steel axle housings
Patterns and Plates Foam patterns made by moldings Template with suction box
Sand Box Bottom or five sides exhaust Four sides exhaust or with exhaust pipe
Plastic Film The top cover is sealed by plastic films All sides of both halves of sand box are sealed by plastic films
Coating Materials Water-based paint with thick coating Alcohol-based paint with thin coating
Molding Sand Coarse dry sand Fine dry sand
Vibration Molding 3 D Vibration Vertical or Horizontal Vibration
Pouring Negative Pouring Negative Pouring
Sand Process Relieve negative pressure, turn over the box to drop sand, and the sand is then reused Relieve negative pressure, then the dry sand falls into the screen, and the sand is recycled


Lost Foam Casting Foundry of Grey & Ductile Iron, Aluminium and Alloy Steel

Lost Foam Casting, also called Lost Foam Casting (LFC) or Full Mold Casting, is a kind of Evaporative Pattern Casting (EPC) with dry sand casting process. The EPC is sometimes could be short for Expendable Pattern Casting because the lost foam patterns could be used only once.

After the foam patterns are finished by special machining, then the foamed plastic patterns are coated with refractory coating to form a strong shell to withstand the molten metal. The foam patterns with shells are put into the sand box, and fill it with dry sand sand around them. During pouring, the high-temperature molten metal makes the foam pattern pyrolyzed and “disappears” and occupies the exit cavity of the patterns, and finally the finished desired castings are obtained.


Foam Patterns

Foam Patterns


Capabilities of Lost Foam Casting at RMC Foundry :

  • Max Size: 1,000 mm × 800 mm × 500 mm
  • Weight Range: 0.5 kg - 100 kg
  • Annual Capacity: 2,000 tons
  • Tolerances: On Request
  • Heat Treatment: Annealing, normalizing, quenching, tempering...etc
  • Custom Service: Available



Foam Pattern Coating

Foam Patterns


Advantages of Lost Foam Castings:

  • 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



Foam Pattern Coating

Foam Patterns


Procedures of Lost Foam Casting Process

  1. Use foam molds to produce foam patterns and casting gating systems
  2. Bond the patterns and runners to form a mold bundle module
  3. Dip paint on the module
  4. Dry the paint
  5. Put the module into the sand box and fill it with dry sand
  6. Vibrate molding in order to fill the cavity with dry sand and then compact the molding sand
  7. Pouring molten metal to vaporize the foam and then forming the desired castings
  8. After the castings have cooled, clean the castings. The dry sand can be recycled



Foam Patterns

Foam Patterns


Ferrous & Non-Ferrous Metals for Lost Foam Castings


  • Cast Iron: Ductile Iron (EN-GJS-400 ~ EN-GJS-800, GGG40 ~ GGG80), Gray Iron (EN-GJL-100 ~ EN-GJL-350, GG10 ~ GG40)
  • Carbon Steel: Low carbon, medium carbon and high carbon steel from AISI 1020 to AISI 1060.
  • Cast Alloy Steel: ZG20SiMn, ZG30SiMn, ZG30CrMo, ZG35CrMo, ZG35SiMn, ZG35CrMnSi, ZG40Mn, ZG40Cr, ZG42Cr, ZG42CrMo...etc on request.
  • Stainless Steel: AISI 304, AISI 304L, AISI 316, AISI 316L and other stainless steel grade
  • Aluminium, Brass and other metal with their alloys.





Foam Patterns

Foam Patterns



Value Added Service of Lost Foam Casting

RMC provides a comprehensive line of lost foam equipment, including flask pouring, flask handling and flask compaction. Our line of foam bead processing equipment is recognized world wide as one of the leading ones.

  • Engineering team whose members are focusing on metal casting field.
  • Extensive experience with complex geometries parts
  • A broad range of materials, including ferrous and non-ferrous alloys
  • In-house CNC machining capabilities
  • One stop solutions for castings and secondary process
  • Consistent quality guaranteed and continuous improvement.
  • Teamwork including toolmakers, engineers, foundryman, machinist and production technicians.


Lost Foam Casting Patterns

Lost Foam Casting Patterns